Fabrication and machinability study of Zn-Al-TiC composite using wire EDM with different dielectric media

Abstract

ABSTRACTMetal matrix composite (MMC) with matrix material as Zinc-Aluminium alloy ZA-27 and reinforcement as 5% TiC ceramic particles is fabricated in the present study. This MMC is prepared in an electric furnace and subsequently machined on a wire electric discharge machine (WEDM). Taguchi’s L27 orthogonal array (OA) is applied with four WEDM parameters: pulse ON time (POT), current (I), pulse OFF time (PFT) and dielectric fluid (DF). To investigate the effect of these parameters on the kerf width (Kw), surface roughness (Ra) and material removal rate (MRR); each of the parameter were individually varied at three different levels. The output responses are analysed using the Entropy-based Measurement of Alternatives and Ranking according to the Compromise Solution (MARCOS) approach. The optimum condition for multiple responses is found at (POT)3 (I)1(PFT)3(DF)2 i.e. pulse ON time at 60 µs, current at 2 A, pulse OFF time at 5 µs and dielectric fluid as vegetable oil. The surface and edge morphology of the machined part is evaluated using SEM micrographs.