Experimental Investigation of Machining Characteristics for the WEDM of Al/ZrO2(p)–PRMMC

Presented is an experimental investigation of the machining characteristics and the effect of wire electrical discharge machine (WEDM) process parameters during machining of Al/ZrO2(p) particulate reinforced metal matrix composite (PRMMC). Experiments are carried out 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 cutting velocity and surface roughness. Taguchi method based design of experiment and L36 (2138) mixed orthogonal array have been used for experimental investigation. Servo control mean reference voltage and wire feed rate have been identified as most significant and significant parameter for cutting velocity so called for material removal rate. Time between pulses and short pulse time have been identified as most significant and significant parameter for surface roughness height, Ra (µm). Optimum response characteristics estimated and identified the range of predicted confidence interval at 95% confidence level is 7.459 to 9.995 mm/min. for cutting velocity and 0.602 to 1.261 (µm) for surface roughness height Ra, respectively.