Mathematical modeling of electric discharge machining of cast Al–4Cu–6Si alloy–10 wt.% SiCP composites

Aluminum matrix composites (AMC) are hard to machine due to the presence of hard and brittle ceramic reinforcements. Electrical discharge machining (EDM) is an important process for machining such materials. The present work evaluates the effect of current (c), pulse-on time (p) and air gap voltage image on metal removal rate (MRR), tool wear rate (TWR), radial over cut (ROC) on electric discharge machining of Al–4Cu–6Si alloy–10 wt.% SiCP composites. The experiments were performed in a systematic manner with three successive trials using a PS LEADER ZNC EDM machine and a cylindrical brass electrode of 30 mm diameter. Three factor, three level full factorial design was adopted for analyzing the results. A second order, non-linear mathematical model has been developed for establishing the relationship among machining parameters. Analysis of variance (ANOVA) has been performed to verify the fit and adequacy of the developed mathematical models.