Investigation to study the effect of WEDM parameters on the dimensional deviation during machining of hybrid aluminum metal matrix composite

Abstract

Wire electric discharge machining (WEDM) is an unconventional machining method employed in the manufacturing sector to precisely cut intricate forms and contours in materials such as the Al-SiC-ZrO₂ hybrid nanocomposite, which is notoriously challenging to machine. This investigation focused on the effect of WEDM parameters specifically pulse-on-time (T_ON), pulse-off-time (T_OFF), peak current (I_P), and wire feed (W_F) on dimensional deviation (DD) while machining the Al-SiC-ZrO₂ hybrid nanocomposite material. The Box–Behnken design, a statistical experimental design technique, was used for experimentation. Response surface methodology investigated the relationship between the input and output variables. The results indicated that the most significant factors affecting DD were T_ON, T_OFF, and I_P. The desirability function approach was employed to determine the optimal values of the WEDM parameters that significantly impacted DD. Confirmation experiments were then conducted under the optimal conditions to validate the predicted model. The results obtained from the confirmation experiments under optimal conditions agreed well with the predicted results.

Keywords

Wire electric discharge machining Box–Behnken design desirability approach dimensional deviation analysis of variance

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