Optimization of WEDM control parameters for machining of functionally graded Al6061-10 %Al2O3 composite

Abstract

Functionally Graded Metal Matrix Composites (FGMMCs) are the advanced developing engineering substance due to its different gradient properties within the single element. Machining is one of the major challenging subjects in the FGMMCs due to its hard ceramic particles. The objective of this experimentation is to make aluminium reinforced with 10% alumina (Al2O3) FGMMC using Horizontal centrifugal casting technique and machine the fabricated specimen using Wire Electric Discharge Machining (WEDM) with varying levels of control variables such as wire feed rate (1, 2 and 3 mm/min), pulse on time (1, 2.5 and 3 μs) and pulse off time (12, 16 and 18 μs). Optimization was performed to derive the optimal output responses such as highest Material Removal Rate (MRR) and smallest Surface Roughness (Ra) using Taguchi’s technique. The optimum operation parameters obtained from this study to get the highest MRR are wire feed rate 2 mm/min, pulse on time 3 μs and pulse off time 18 μs and smallest surface roughness are wire feed rate 1 mm/min, pulse on time 3 μs and pulse off time 12 μs.