Parametric optimization for sustainable WEDM of different profile cut on hybrid metal matrix composites

Abstract

In this work, an experiment was performed on the WEDM to cut three different AMMC (Aluminium metal matrix composites), which were fabricated by a stir casting process. To fabricate AMMC, Al6061 was chosen as a matrix, and Alumina and Silicon carbide were selected as reinforcement materials. 1st AMMC was fabricated by using 10 % Al2O3, 2nd fabricated with 10 % SiC, and the third HMMC was fabricated by mixing 5 % alumina and 5 % SiC both. And BBD (box behnken design) approach of RSM (Response surface modelling) was used to develop an experimental design for input parameters such as pulse on time (30 µs-50 µs), pulse off time (6 µs-12 µs), and current(1Amp-5Amp) on cutting of three different shapes such as triangle, circle, and square for CV and SR responses. And experimental data was performed by using the BBD approach was optimized by MOPSO, and it was found that for AMMC/Al2O3 Ton = 30 µs, Toff = 12 µs, I = 1 Amp, and triangle profile were optimal input parameters. And for AMMC/SiC and AMMC/Al2O3/SiC, Ton = 30 µs, Toff = 6 µs, I = 1 Amp, and triangle profile was optimal input parameters. And from phase analysis by XRD, it show the proper mixing of reinforcement in matrix.