An experimental analysis of machining characteristics and parametric optimization for the WEDM of Al/ZrO_2(p) - PRMMC

This paper presents an experimental investigation of the machining characteristics and the effect of wire electrical discharge machining process parameters during machining of newly developed Al/ZrO_2(p) particulate reinforced metal matrix composite (PRMMC). Experiments have been carried out in order to investigate the effects of input parameters such as dielectric conductivity, pulse width, time between pulses, maximum feed rate, servo control mean reference voltage, short pulse time, wire feed rate, wire mechanical tension and dielectric injection pressure on performance measures like spark gap and material removal rate. The optimal setting of parameters has been determined through experiments planned, conducted and analyzed using Taguchi method. L_36 mixed orthogonal array (2^1x3^8) has been selected to design the experiments. The significant parameters have also been identified and their effect on performance measures has been studied. The results obtained have been validated by conducting the confirmation experiments. The newly developed metal matrix composite can be used in aerospace industries.