Effect of Various Parameters on Response Characteristics of WEDM during Machining of Al/SiCp-MMCs

Abstract

In this experimental study, wire cut electrical discharge machining (WEDM) is adopted in machining of silicon carbide particulate reinforced aluminium metal matrix composites (Al/SiCp-MMCs). In the experiments total six machine input parameters are varied using one factor at a time strategy to explore their effect on response characteristics including cutting speed, surface roughness and spark gap. Moreover Wire breakage was found to pose limitations on the cutting speed of MMCs. The present study also investigates the causes of wire breakage in machining of Al/SiCp-MMCs and suggests their remedial actions. Reinforcement percentage of SiC particles and pulse on time are found to have significant effect on the response characteristics. Test results reveal that in machining of Al/SiCp-MMCs, higher cutting speed could be achieved with optimum setting of pulse off time and spark gap set voltage without wire breakage. Additionally high wire feed rate, a high flushing rate and setting of optimum wire tension is required to avoid wire breakage. An optimum range of machine input parameters has been reported as the outcome of this work for the successful machining of Al/SiCp-MMCs with minimum chances of wire breakage for further research in this area.