Modeling and desirability approach-based multi-response optimization of WEDM parameters in machining of aluminum metal matrix composite

Abstract

The study presents machining aspects of particulate silicon carbide reinforced aluminium metal matrix composite (Al/SiCp-MMC) using wire-cut electric discharge machining process. The influences of process parameters such as pulse on time, pulse off time, spark gap voltage, peak current, wire tension and wire feed rate on response variables such as workpiece cutting speed, surface roughness (Ra) and spark gap have been investigated. The Box–Behnken’s design has been utilized to plan the experiments, and response surface methodology is employed for developing quadratic regression models for selected response variables. Desirability function approach has been used to solve the multi-response optimization problem by assigning the weightages to the selected responses as per the user’s requirement of quality or productivity. The study recommends optimal process conditions such as pulse on time 0.75 µs, pulse off time 16 µs, spark gap voltage 35 V, peak current 120 A, wire tension 1200 g, and wire feed rate 10 m/min for effective machining of Al/SiCp-MMC, which has been validated by conducting confirmation experiments. The developed regression models for selected responses revealed compatible results, thereby justifying their acceptability.