An Estimating the Effect of Process Parameters on Metal Removal Rate and Surface Roughness in WEDM of Composite Al6063/SiC/Al2O3 by Taguchi Method

Open access


The present study was focused on the fabrication of metal matrix and hybrid metal matrix composites through stir casting process. The Aluminium 6063 was used as base material and SiC/Al2O3 were used as reinforcement with varying weight %. The parametric study on a wire-cut electro discharge machine was carried out by using Taguchi Method. A statistical analysis of variance (ANOVA) was performed to identify the process parameters that were statistically significant. It was observed that the MRR decreases with increase in the percentage weight fraction of SiC and Al2O3 particles in the MMCs and HMMCs. Whereas, the surface roughness parameter increases with increase in the percentage weight fraction of SiC and Al2O3 particles due to the hardness of MMCs and HMMCs composites.

[1] N. Chawla, Y.N. Shen. Mechanical Behaviour of Particle Reinforced Metal Matrix Composites, Adv Eng Mater 2001 (3), 357 - 370

[2] K.H. Newman, S.T. Rahimifard, S. Allen. State of art in wire electrical discharge machining, International. Int J Mach Tool Manu, 2004 (44), 1247 - 1259.

[3] H.P. Raturi, M. Pokhriyal, L. Prasad. Parametric effects on metal matrix composite and hybrid metal matrix composite machining through WEDM –a review, 1st national conference on “recent advance in science and technology”, August 22-23, 2015; SIT, Pithoragarh, Uttarakhand (INDIA), ISBN: 978-93-85437-03-8

[4] A. Handa, V. Chawla. Experimental evaluation of mechanical properties of friction welded dissimilar steels under varying axial pressures, Journal of Mechanical Engineering - Strojnícky časopis, 2016 (66), No. 1, 27 - 36.

[5] V. K. Patel, K. Rani. Mechanical and Wear Properties of Friction Stir Welded 0-6wt% nAl2O3 Reinforced Al-13wt% Si Composites, Journal of Mechanical Engineering - Strojnícky časopis, 2017 (67), No. 1, 77 - 86

[6] D. Santha Rao, N. Ramanaiah. Process Parameters Optimization for Producing AA6061/TiB2 Composites by Friction Stir Processing, Journal of Mechanical Engineering - Strojnícky časopis, 2017 (67), No. 1, 101 - 118

[7] R. Jančo, L. Écsi, P. Élesztős. FSW Numerical Simulation of Aluminium Plates by Sysweld - Part II, Journal of Mechanical Engineering - Strojnícky časopis, 2016 (66), No. 2, 29 - 36

[8] S. Lal, S. Kumar, Z.A. Khan, A.N. Siddiquee. Wire electrical discharge machining of AA7075/SiC/Al2O3 hybrid composite fabricated by inert gas-assisted electromagnetic stir casting process. J Braz Soc Mech Sci Eng 2014 (36), 335 - 346.

[9] K. Hemalatha, V.S.K. Venkatachalapathy, N. Alagumurthy. Surface Integrity analysis in Wire-Cut Electric Discharge Machining of Al 6063/Al2O3 Metal Matrix Composite through Response Surface Methodology. Applied Mechanics and Materials 2014 (592-594), 534 - 539.

[10] D. Satishkumar, M. Kanthababu, V. Vajjiravelu, R. Anburaj, N.T. Sundarrajan, H. Arul. Investigation of wire electrical discharge machining characteristics of Al6063/SiCp composites. Int J Adv Manuf Technol 2011 (56), 975 - 986.

[11] K.L. Meena, A. Manna, S.S. Banwati, Jaswanti. Effect of wire feed rate and wire tension during machining of pr-Al-SiC-MMCs by WEDM, European Journal of Engineering and Technology 2013 (1), 1 - 13.

[12] A. Sharma, M.P. Garg, K.K. Goyal, Prediction of optimal conditions for WEDM of Al 6063/ZrSiO4 (p) MMC. Procedia Materials Science 2014 (6), 1024 - 1033.

[13] S.K. Garg, A. Manna, A. Jain. An Experimental Investigation for Optimization of WEDM Parameters during Machining of Fabricated Al/ZrO2 (p)-MMC. Arab J Sci Eng, 2013 (38), 3471 - 3483.

[14] R.K. Fard, R.A. Afza, R. Teimouri. Experimental investigation, intelligent modelling and multi-characteristics optimization of dry WEDM process of Al–SiC metal matrix composite, Manuf Process 2013 (15), 483 - 494.

[15] M. Ramachandra, K. Radhakrishna. Sliding wear, slurry erosive wear, and corrosive wear of aluminium/SiC composite. J Mater Sci 2006 (24), 333 - 348.

[16] M.D. Bermudeza, G.M. Niccolas, F.J. Carrion, I.M. Mateoa, J.A. Rodríguez, E.J. Herrera. Dry and lubricated wear resistance of mechanically-alloyed aluminium-base sintered composites. J Wear 2001 (248), No. 1-2, 178 - 186.

[17] V.S. Aigbodin, S.B. Hassan. Effects of Silicon carbide reinforcement on Microstructure and properties of cast Al – Si – Fe / SiC particulate composites. J Mater Sci Eng 2007 (447), 355 - 360.

[18] E.B. Dean, R. Unal, Taguchi approach to design optimization for quality and cost: An overview. NASA Technical Report. NASA Langley Research Centre; Hampton, VA, United States. 1990.

[19] D. Ghodsiyeh, A. Golshan, J.A. Shirvanehdeh. Review on Current Research Trends in Wire Electrical Discharge Machining. Indian J Sci Techno 2013, 4128 - 4140.

Journal Information

CiteScore 2018: 1.61

Source Normalized Impact per Paper (SNIP) 2018: 0.350


All Time Past Year Past 30 Days
Abstract Views 0 0 0
Full Text Views 296 217 23
PDF Downloads 154 143 11