Mathematical Modeling and Analysis of Surface Roughness in EDM of AA6061wt. 15% B4Cp MMC through RSM

In the present study, the mathematical model was developed to investigate the effects of current, pulse on time and pulse off time in EDM performance on surface roughness during machining of AA6061 wt.15% B₄C_p metal matrix composite. The aluminum composite is prepared by taking weight. 85% of AA6061 and weight. 15% of B₄C_p through stir casting technique. In order to analyze the machinability of aluminum composite, the experimental design was planned as per Box-Behnken design (BBD). The modeling and optimization of electric discharge machining has been done using Design Expert software 7.0. The validity test of the fit and adequacy of the proposed model for surface roughness has been carried out through analysis of variance (ANOVA). The percentage error between the predicted values and the experimental values of response factors obtained through confirmation experiments are within 5%. From the analysis, it is evident that current and pulse on time was found to have significant effect on surface roughness.