Optimization of Die-Sinking EDM Process Parameters in Machining OF AMMC-Desirability Approach

Abstract

Metal Matrix Composites (MMCs) are one of the recent advanced materials having the properties of light weight, high specific strength and high wear resistance which are essential in Aircraft fittings, gears and shafts, missile parts, regulating valve parts, aerospace and defence applications. In the present work, Orthogonal Array L27 Taguchi Experimental design is prepared using Minitab software by considering material parameters: type of the base material (Al5052, Al6082, Al7075), type of reinforcement material (FlyAsh, SiC,Al2O3), percentage of the reinforcement(2. 5, 5%, 10%) and machining parameters current (Ip), pulse on time (Ton), pulse off time (Toff), tool lifting time(TL). AMMC samples are fabricated using stir casting process and experiments have been performed on these samples by using electro discharge machining(EDM) as per Taguchi design of experiments and the responses such as Material removal rate (MRR), surface roughness (SR), and Electrode wear rate (EWR) and cost are measured. The experimental response data of electro discharge machining process is analysed and the optimal combinations of influential parameters are determined using Desirability Function Analysis. Based on these optimum parameters combinations conformation test has been carried out and predicted results have been found to be in good agreement with experimental findingshardness, toughness, and good thermal resistance properties as compared to unreinforced alloys.