Experimental investigation of edm processing parameters on machining al6063-12% sic-5% gr using response surface methodology

Composite materials have been active subjects of scientific investigation and applied research for the last decade. Recently, the reaction processed metal matrix composites (MMCs) have been spot lighted in the development of an enhanced interface structure. This stems from the realization that a deeper understanding of fundamentals is needed for composites to become more broadly useful. This paper investigated the effect of process parameters such as current, pulse-on time, pulse-off time, and gap voltage on material removal rate (MRR), tool wear rate (TWR), and delamination factor (DF) in aluminum MMCs consisting of aluminum alloy (Al6063). The Al6063 alloy is reinforced with 12% SiCp and 5% graphite particles (by weight fraction) prepared by stir-casting process. The Z axis numerical controlled electric discharge machine (ZNC-EDM) is used for carrying out experiments using the response surface methodology (RSM) approach. Mathematical equations were developed based on the experimental data for the prediction of output parameters. From this study, it was found that pulse-on time, current, and gap voltage have significant impact on MRR. The DF is found to be low for lower current and lower gap voltage. Pulse-on time and current found to have notable influence on TWR.