Multiple Performance Optimization in WEDM Parameters Using Desirability Analysis

Abstract

In this article, the effect of wire electrical discharge machining (WEDM) parameters such as pulse-on time (TON), pulse-off time (TOFF), and wire feed (F) on material removal rate (MRR) and surface roughness in metal matrix composites (MMCs) consisting of aluminium alloy (A1356) silicon carbide (SiCp) and Mica is discussed. The Al 356 is reinforced with SiCp and Mica in the form of particulates. The experiments are carried out as per design of experiments approach using L9 orthogonal array. The optimum machining parameters have been identified by a composite desirability value obtained from desirability function analysis as the performance index, and significant contribution of parameters can then be determined by analysis of variance (ANOVA). Confirmation test is also conducted to validate the test result. Experimental results have shown that machining performance can be improved effectively through this approach. The results were analysed using analysis of variance and response graphs. It is found that different combinations of WEDM process parameters are required to achieve higher MRR and minimum surface roughness for composites. These results will be useful for manufacturing engineers to select appropriate WEDM process parameters to machine MMCs of Al 356 reinforced with SiC and Mica.