Optimization of process parameters on wire cut electrical discharge machining and surface integrity studies of AA6070/MgO composites

Abstract

Abstract There are a variety of uses for metal matrix composites (MMC), including the aerospace and automotive industries. Because of their benefits including light weight and inexpensive cost, they are popular. Wire cut electric discharge machining (WEDM) stands out as a great option for creating complex or complicated shapes out of composite materials, especially when compared to other common non-traditional machining processes. An AA6070 metal matrix composite containing 5% and 10% MgO weight fraction (wt) was made using the stir casting method in this work. Various process factors, such as wire tension (WT), dielectric pressure (Pd), gap voltage (Vg) and peak current (IP) are taken into account when the AMMC specimen is machined utilising WEDM. Slot machining rate (MR) and surface roughness (Ra) can be measured and assessed using L18 mixed Orthogonal Array (OA) investigations. Experiments are examined using TOPSIS and ANOVA methodologies for order preference based on similarity to the ideal results (ANOVA). Analysis has shown that the best mixture of processing factors for improved MR and Ra: wt = 5%, vg = 50 V, WT = 13 g, Ip = 9 A, and Pd = 15 bar. Machining Rate and Ra have ideal process parameters of 1.5 mm/min and 3.648 m. ANOVA shows that MR and Ra are significantly influenced by peak current.