International Journal of Vehicle Structures and Systems

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Parametric Optimization of Wire Cut Electrical Discharge Machining on Al-9% PAC Composites using Desirability Approach


Affiliations
1 Dept. of Aero. Engg., ACS College of Engg., Bangalore, India
 

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In aerospace and automobile industries manufacturing complex structures using un-conventional machining is increased due to their precision and accuracy. This research investigates the influence of input parameters such as discharge current, pulse on time, pulse off time and servo speed rate of wire cut electrical discharge machining (WEDM) on material removal rate and surface roughness using Box Behnken design supported with response surface methodology. Aluminium alloy 7075 reinforced with 9 % wt. of activated carbon composite is used to carry out the machining process. Most influencing parameters are subjected as the conductive and non-conductive parameters in WEDM process. To find out the significant influence of each factor, analysis of variance was performed. The mathematical model is established using desirability technique and then the optimal machining parameters are determined. The best achieved WEDM performances - material removal rate and surface roughness are 10.46 mm3/min and 3.32μm respectively, by using optimum machining conditions - discharge current 2000mA, pulse on time 8.9µs, pulse off time 25µs and servo speed rate 150rpm at 0.8597 desirability value.

Keywords

Wire Cut Electrical Discharge Machining, Aluminium Composites, Response Surface Methodology, Desirability Method.
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  • Parametric Optimization of Wire Cut Electrical Discharge Machining on Al-9% PAC Composites using Desirability Approach

Abstract Views: 281  |  PDF Views: 141

Authors

G. Ramanan
Dept. of Aero. Engg., ACS College of Engg., Bangalore, India
R. Elangovan
Dept. of Aero. Engg., ACS College of Engg., Bangalore, India

Abstract


In aerospace and automobile industries manufacturing complex structures using un-conventional machining is increased due to their precision and accuracy. This research investigates the influence of input parameters such as discharge current, pulse on time, pulse off time and servo speed rate of wire cut electrical discharge machining (WEDM) on material removal rate and surface roughness using Box Behnken design supported with response surface methodology. Aluminium alloy 7075 reinforced with 9 % wt. of activated carbon composite is used to carry out the machining process. Most influencing parameters are subjected as the conductive and non-conductive parameters in WEDM process. To find out the significant influence of each factor, analysis of variance was performed. The mathematical model is established using desirability technique and then the optimal machining parameters are determined. The best achieved WEDM performances - material removal rate and surface roughness are 10.46 mm3/min and 3.32μm respectively, by using optimum machining conditions - discharge current 2000mA, pulse on time 8.9µs, pulse off time 25µs and servo speed rate 150rpm at 0.8597 desirability value.

Keywords


Wire Cut Electrical Discharge Machining, Aluminium Composites, Response Surface Methodology, Desirability Method.

References





DOI: https://doi.org/10.4273/ijvss.10.6.16