Experimental Investigation and Optimization of Material Removal Rate and Tool Wear in the Machining of Aluminum-Boron Carbide (Al-B4C) Nanocomposite Using EDM Process

Abstract

Electrical discharge machining (EDM) is a cost-effective unconventional machining method used for machining any composites materials. EDM is based on the thermoelectric energy between the electrode and workpiece. In this work, boron carbide particles of 50 nm (6 wt.%) are reinforced with aluminum 7075 (94 wt.%) prepared using stir casting method. The stir casting process is carried out at speed of 700–800 rev/min. The fabricated aluminum-boron carbide nanometal matrix composites are used as workpiece (anode); copper electrode is used as tool (cathode). This work investigates the influence of EDM process parameters such as current (I), pulse on-time (ton), and tool diameter (d) during machining of Al-B4C composite on metal removal rate (MRR) and tool wear rate (TWR). The design of experimental plan is executed by Taguchi approach, and the responses of each parameter are influenced by analysis of variances (ANOVA). Response table for average value of MRR and TWR shows that the current is the significant parameter affecting MRR and TWR. From this work, it was observed that material removal rate increased with increasing the current, and the tool wear rate decreases.