Abstract
This experimental investigation aims to optimize wire electrical discharge machining (WEDM) process parameters of Al-Al3Fe in-situ composites prepared by reactive stir casting route. Following a robust design lay-out of Taguchi L27 array, WEDM tests have been carried out by varying one material parameter namely, volume percent of reinforcement (VR), and three machining parameters namely, pulse-on time (Ton), servo voltage (Sv) and peak current (Ip); whereas, the material removal rate (MRR) and surface roughness (SR) are considered as output responses. The influences of input parameters on MRR and SR are statistically quantified by ANOVA. Significant process parameters are identified as Ton (69%), Sv (19%) and Ip (7.74%) on MRR; while only Ton (39%) on SR. MRR and SR values are found to be minimum for 20 vol% Al3Fe reinforced composite. Predictive models are generated considering full quadratic response surface equations and validated through several confirmatory tests. Besides, the desirability approach has been adopted for multi-response optimization of MRR and SR; the obtained solutions are affirmed by conducting new tests, and the related error is estimated at less than ±10%. Considering the robustness of the generated models, these models could be used for predicting WEDM performance of in-situ transitional metal tri-aluminides reinforced Al-matrix composites.
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