Abstract
As newer, more exotic materials are developed, and more complex shapes are presented, conventional machining operations reach their limitations. Hence the increased use of non-conventional machining methods in manufacturing continues to grow at an accelerated rate. In this paper, an attempt has been made to machine Al 6063/ ZrSiO4(p) (5%) metal matrix composite using wire electric discharge machining. The objective is to investigate the influence of process parameters namely pulse on time, pulse off time, peak current and servo voltage on cutting rate. A Box-Behnken design approach of response surface methodology (RSM) is used to plan and analyze the experiments. The mathematical relationships between WEDM input process parameters and response parameter are established to determine optimal values of cutting rate mathematically. The Analysis of variance (ANOVA) and F-test are performed to obtain statistically significant process parameters. The generated optimal process conditions have been verified by conducting confirmation experiments and predicted results have been found to be in good agreement with experimental findings.
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