Investigation of the WEDM Parameters’ Influence on the Recast Layer Thickness of Spark Plasma Sintered SiC-TiB2-TiC Ceramic

Abstract

The influence of WEDM parameters (Spark gap voltage, Pulse-on time, Spark frequency, and Wire speed) on the recast layer thickness and surface roughness of Spark Plasma Sintered SiC-TiB2-TiC ceramic composite was investigated. For this, an orthogonal L9 Taguchi design was used, and grey relational analysis was carried out for multi-response WEDM parameter optimization in order to determine the minimum RLT and SR. It was noticed that for RLT, the Pulse-on time was observed as the most significant process parameter, followed by Spark gap voltage. On the other hand, Spark frequency and Wire speed had no significance for RLT. Moreover, Spark frequency was observed as the most significant process parameter, followed by Pulse-on time and Spark gap voltage, while Wire speed had a negligible effect on SR. It was found that at optimal process parameters (U = 48V; Ton = 1.0 µs; f = 10 kHz; q = 8 m/min), we obtained an RLT of 3.16 µm and an SR of Ra = 0.847 µm. The confirmation test showed a decrease in RLT and SR by 43.67% and 7.12%, respectively, in comparison to the initial machining conditions.