<abstract xmlns="http://www.w3.org/1999/xhtml">

The present investigation aimed to determine the optimal parameters for wire-cut electrical discharge machining (WEDM) for stir cast aluminum alloy AA6063 at 850°C reinforced with 10 wt.% green SiC (SiC<italic>g</italic>) and black SiC (SiC<italic>b</italic>) particles. The WEDM machining parameters, such as pulse on time (<italic>TON</italic>), wire feed (WF) rate, and flushing pressure (FP) of the resultant stir cast AA6063/SiC<italic>b</italic> and AA6063/SiC<italic>g</italic> composites, were optimized using the Taguchi method with L9 orthogonal array to estimate the responses, such as surface roughness and metal removal rate. Further, through grey relational analysis, the finest parameters for WEDM of AA6063/SiC<italic>b</italic> and AA6063/SiC<italic>g</italic> composites were evaluated as <italic>TON</italic> = 50 μs, WF rate = 18 m/min, and FP = 3 MPa. With the optimum parameters obtained, conformational experiments were conducted, and the scanning electron microscopic images were recorded, along with the energy-dispersive X-ray (EDX) spectroscopic data of the worn surfaces and debris. From the EDX mapping images of the machined surface, it was evident that AA6063/SiC<italic>b</italic> displays a more polished surface than AA6063/SiC<italic>g</italic>. However, for applications requiring a high metal removal rate, AA6063/SiC<italic>g</italic> displays better results than AA6063/SiC<italic>b</italic>.
</abstract>

The present investigation aimed to determine the optimal parameters for wire-cut electrical discharge machining (WEDM) for stir cast aluminum alloy AA6063 at 850°C reinforced with 10 wt.% green SiC (SiCg) and black SiC (SiCb) particles. The WEDM machining parameters, such as pulse on time (TON), wire feed (WF) rate, and flushing pressure (FP) of the resultant stir cast AA6063/SiCb and AA6063/SiCg composites, were optimized using the Taguchi method with L9 orthogonal array to estimate the responses, such as surface roughness and metal removal rate. Further, through grey relational analysis, the finest parameters for WEDM of AA6063/SiCb and AA6063/SiCg composites were evaluated as TON = 50 μs, WF rate = 18 m/min, and FP = 3 MPa. With the optimum parameters obtained, conformational experiments were conducted, and the scanning electron microscopic images were recorded, along with the energy-dispersive X-ray (EDX) spectroscopic data of the worn surfaces and debris. From the EDX mapping images of the machined surface, it was evident that AA6063/SiCb displays a more polished surface than AA6063/SiCg. However, for applications requiring a high metal removal rate, AA6063/SiCg displays better results than AA6063/SiCb.

Parameter optimization for wire-cut electrical discharge machining of stir cast AA6063 alloy/SiC (black and green) using Taguchi method with grey relational analysis

Medical Bionanotechnology, Faculty of Allied Health Sciences

Materials Science-Poland

This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

The present investigation aimed to determine the optimal parameters for wire-cut electrical discharge machining (WEDM) for stir cast aluminum alloy AA6063 at...

Parameter optimization for wire-cut electrical discharge machining of stir cast AA6063 alloy/SiC (black and green) using Taguchi method with grey relational analysis

Published Online: Jun 18, 2022

Page range: 68 - 83

Received: Nov 13, 2021

Accepted: Apr 11, 2022

DOI: https://doi.org/10.2478/msp-2022-0011

Keywords
AA6063, silicon carbide, wire-cut electrical discharge machining, stir cast, Taguchi method, grey relational analysis

© 2022 Raj Kumar R et al., published by Sciendo

This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Parameter optimization for wire-cut electrical discharge machining of stir cast AA6063 alloy/SiC (black and green) using Taguchi method with grey relational analysis

Published Online: Jun 18, 2022

Page range: 68 - 83

Received: Nov 13, 2021

Accepted: Apr 11, 2022

DOI: https://doi.org/10.2478/msp-2022-0011

KeywordsAA6063, silicon carbide, wire-cut electrical discharge machining, stir cast, Taguchi method, grey relational analysis

© 2022 Raj Kumar R et al., published by Sciendo

This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Keywords
AA6063, silicon carbide, wire-cut electrical discharge machining, stir cast, Taguchi method, grey relational analysis