Optimization of CNC-WEDM Parameters for AA2024/ZrB2 in situ Stir Cast Composites Using Response Surface Methodology with Desirability Function Technique

Abstract

In recent years, application of aluminum materials in aircraft structures with output responses like maximum material removal rate and minimal surface roughness is at great necessity. This performance is attained during the wire cut electrical discharge machining and is influenced by the extent of ceramic inclusions in the aluminum matrix. The current research focuses on improving the machining performance of as-prepared aluminum zirconium diboride AA2024–ZrB2 prepared at different weight ratios of ZrB2 particles as 0, 2.5, 5, 7.5 and 10 wt%. The as-prepared samples are investigated for different characterizations like phase identification using X-ray diffraction technique; microstructure analysis using both optical microscope and field emission scanning electron microscope; and analysis of mechanical properties using tensile strength and micro-hardness tests. During the machining process, four input parameters like pulse on time Ton (μs), pulse off time Toff (μs), gap voltage GV (V) and ZrB2 wt% are considered for optimization and obtains 23 μs, 41 μs and GV 100 V at 2.5 wt% ZrB2. During machining, multi-response optimization, using response surface methodology with desirability function is performed. The output responses as of maximum material removal rate (MRR) of 0.0765 g/min and minimum surface roughness (SR) of 3.618 μm are obtained. The addition of different wt% ZrB2 in the base matrix has greatly influenced the output response like MRR and SR in the aluminum matrix.