Optimization of machining parameters for EDM operations based on central composite design and desirability approach

Abstract

A novel aluminium metal matrix composite reinforced with SiC particles were prepared by liquid metallurgy route. Recent developments in composites are not only focused on the improvement of mechanical properties, but also on machinability for difficult-to-machine shapes. Electrical discharge machining (EDM) was employed to machine MMC with copper electrode. using EDM. Experiments were conducted using pulse current, gap voltage, pulse on time and pulse off time as typical process parameters. The experiment plan adopts face centered central composite design of response surface methodology. Analysis of variance was applied to investigate the influence of process parameters and their interactions viz., pulse current, gap voltage, pulse on time and pulse off time on material removal rate (MRR), electrode wear ratio (EWR) and surface roughness (SR). The objective was to identify the significant process parameters that affect the output characteristics. Further a mathematical model has been formulated by applying response surface method in order to estimate the machining characteristics such as MRR, EWR and SR.