Investigation of wire electrical discharge machining characteristics of Al6063/SiCp composites

In this investigation, the effect of wire electrical discharge machining (WEDM) parameters such as pulse-on time (T (ON)), pulse-off time (T (OFF)), gap voltage (V) and wire feed (F) on material removal rate (MRR) and surface roughness (R (a)) in metal matrix composites (MMCs) consisting of aluminium alloy (Al6063) and silicon carbide (SiCp) is discussed. The Al6063 is reinforced with SiCp in the form of particles with 5%, 10% and 15% volume fractions. The experiments are carried out as per design of experiments approach using L-9 orthogonal array. The results were analysed using analysis of variance and response graphs. The results are also compared with the results obtained for unreinforced Al6063. From this study, it is found that different combinations of WEDM process parameters are required to achieve higher MRR and lower R (a) for Al6063 and composites. Generally, it is found that the increase in volume percentage of SiC resulted in decreased MRR and increased R (a). Regression equations are developed based on the experimental data for the prediction of output parameters for Al6063 and composites. The results from this study will be useful for manufacturing engineers to select appropriate WEDM process parameters to machine MMCs of Al6063 reinforced with SiCp at various proportions.