Effect of process parameters on the electrical discharge machining of aluminum metal matrix composites through a response surface methodology approach

Abstract This work presents the multiobjective optimization of machining parameters during the electrical discharge machining (EDM) of aluminum (Al)-silicon carbide (SiC) metal matrix composites (MMC). The process parameters considered were current, pulse on-time, dielectric flushing pressure, and SiC particles. A copper rod was used as an electrode. An Al-SiC MMC with Al 6061 as matrix and SiC particles having three different sizes (i.e., 15, 25, and 40 μm) were used as workpieces. The experiments were planned using design of experiments through response surface methodology (RSM). The mathematical models were developed to predict the better performance measures such as the material removal rate (MRR), electrode wear rate (EWR), surface roughness (SR), and cylindricity (CY). The desirability approach in RSM was performed for optimization. It was found that the MRR increases with increasing peak current, pulse on-time, flushing pressure, and particle size. The EDM parameters are to be analyzed for the MRR, EWR, SR, and CY. The best one is proposed for validation.