Exploration on WEDM process parameters effect on LM13 alloy and LM13/SiC composites using Taguchi method

Abstract

In manufacturing sectors and the automobile field’s aluminium and aluminium based composites usage in various range of applications owing to their higher physical and mechanical properties. Wire electrical discharge machining process is a highly complex, time varying & stochastic process. The process output is affected by input variables. Therefore a suitable selection of input variables for the wire electrical discharge machining (WEDM) process relies heavily on the operator's technology & experience due to wide range of demand. Metal removal rate (MRR) & surface finish (Ra) are sought to obtain precision work. Using Taguchi's parameter design, significant machining parameters affecting the performance measures are identified as pulse off time (Toff), pulse on time (Ton) and input current (amps). In the present study, first experimentation on LM13 aluminium alloy and LM13/SiC composites has been fabricated by squeeze casting process under optimal parametric condition to attain better hardness and tensile strength. In second phase of examination the machinability study were carried out of LM13 alloy and LM13/SiC composites through WEDM techniques input process variables such as pulse on time (Ton, 30–40 µs), pulse off time (Toff, 4–10 µs) and peak current (Ip, 1–3 Amp) on response of material removal rate (MRR) and surface roughness (Ra). The L9 OA Taguchi method was implemented for calculating the machining characteristics. The effect of each control factor on the performance measure is studied individually using the plots of signal to noise (S/N) ratio. The study demonstrates that the WEDM process parameters can be adjusted so as to achieve better metal removal rate and surface finish. Therefore, the optimal set of WEDM parameters is suggested for all manufacturing sectors.