Abstract
The present study focused on the multiple regression modeling and predicting the surface roughness of the Aluminum hybrid composite during the WEDM process. The hybrid MMC was manufactured by process named as stir casting utilizing particulates of Silicon carbide and graphite each in Al6061 combination. The analyses were outlined with Taguchi L27 design matrix. Mathematical relationships between the surface roughness and WEDM cutting parameters (Pulse on time, Pulse off time, current, gap voltage, wire speed and wire tension) have been investigated. The results show that the multiple regression analysis is a successful method for developing a mathematical model to predict the surface roughness. The optimum value of process parameters for the predicted optimum value of surface roughness (1.285) is pulse on time 106 units (Level 1), pulse off time 60 units (Level 3), peak current 90 units (Level 2), gap set voltage 50 units (Level 3), wire speed3 units (Level 1) and wire tension 12 units (Level 3).The optimum results are adopted in validation study and the results based on WEDM process responses can be effectively improved.
Highlights
Running with the progression of the mechanical era, the solicitations for composite materials having high hardness, quality, wear assurance, and disintegration security are growing [1]
Lower Kerf width.The present study focuses on the modeling and prediction techniques to determine direct effects of WEDM parameters (Pulse on time, Pulse off time, current, gap voltage, wire speed and wire tension) on the surface roughness which is important for cutting dies and complex shapes
Proper selection of machining parameters is an important step in the WEDM process, which leads to better machining performance
Summary
Running with the progression of the mechanical era, the solicitations for composite materials having high hardness, quality, wear assurance, and disintegration security are growing [1]. Metal system composites discover applications in air space industry and auto applications in perspective of their light weight, high particular quality and uncommon wear safe. Electrical release machining is one of the nonconsistent machining outlines which have been completely used to pass on jumble shapes, bombs hopelessly and shapes [5]. It is utilized for completing parts for air space and automobile industry [6].
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