Experimental Investigation, Parametric Optimization, and Cost Analysis in EDM of Aluminium-Silicon Carbide Metal Matrix Composite

Abstract

The objectives of this investigation were to find out the optimal cutting parameters and to predict the tool wear rate using a brass electrode in electrical discharge machining process for aluminium-silicon carbide metal matrix composite. The cutting parameters investigated in this research included discharge current, gap voltage, pulse-on time, pulse-off time and flushing pressure with vegetable oil-based dielectric fluid. Additionally, the response surface methodology (RSM) and analysis of variance (ANOVA) are employed, respectively, for experimental analysis, predictive modeling, and process optimization based on the Box-Behnken design of Experiments (BBDoEs). Then, the most appropriate optimal solution is used for cost-effective analysis. Subsequently, the performance of suggested RSM optimization method is estimated from the confirmation test. Finally, the economic analysis has been performed using a novel approach to evaluate the total machining cost for each part of rupees Rs. 151.69 during machining of aluminium-silicon carbide metal matrix composite under optimal machining conditions. Results were further analyzed using SEM study to investigate the cause of discharge current on topographical features of the machined surface.