Synthesis of Stir-Cast AA7050/5%B4C Composite and Optimization of EDM Response Parameters Using Taguchi Analysis

Abstract

Machining of Automobile and aerospace components are the prime concern for close tolerance and eastern mechanical design. AA7050 is the established aluminium alloy for automobile and aerospace components. AA7050/B4C composite enhances specific strength and wear property of the alloy. The present paper aims to develop AA7050/5%B4C Composite through flux assisted Stir casting method. Characterized its microstructure for proper distribution and incorporation of the particles. Furthermore, non-conventional machining done on the composite through CNC die-sinking EDM with process parameters Peak current (Ip), Pulse on time (Ton), and Pulse off time (Toff). The experiments are designed by Taguchi L9 orthogonal array to obtain the machining responses like Material removal rate (MRR), Surface roughness, (SR) and cutting speed (Cs). Further the responses are optimised using Taguchi analysis considering higher the better criterion for MRR and Cs and lower the better for SR. The optimal set of process parameters obtained for MRR is X3Y3Z2, for SR X3Y2Z3 and Cs X3Y3Z2. The confirmation tests conducted with optimal set of process parameters for each response. The error estimated between predicted and experimental at optimal sets is within the acceptable threshold.