EVALUATION OF MATERIAL REMOVAL RATE AND SURFACE ROUGHNESS IN WIRE ELECTRO-DISCHARGE MACHINING OF 10-WT.% ZrO2-REINFORCED AL ALLOY COMPOSITE

A. Karthikeyan, S. V. Alagarsamy () and C. Ilaiya Perumal ()
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A. Karthikeyan: Department of Mechanical Engineering, University VOC College of Engineering, Anna University Thoothukudi Campus, Thoothukudi 628008, Tamil Nadu, India
S. V. Alagarsamy: ��Department of Mechanical Engineering, Mahath Amma Institute of Engineering & Technology, Pudukkottai 622101, Tamil Nadu, India
C. Ilaiya Perumal: ��Department of Mechanical Engineering, Alagappa Chettiar Government College of Engineering and Technology, Karaikudi, Sivagangai 630004, Tamil Nadu, India

Surface Review and Letters (SRL), 2022, vol. 29, issue 01, 1-11

Abstract: In this study, we optimize the wire electro-discharge machining (WEDM) parameters in zirconia (ZrO2) ceramic particulates-filled Al7075 alloy composite by using the Taguchi-combined Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) method. The Al7075 alloy composite was synthesized via the stir casting route by the addition of 10wt.% of ZrO2 particulates. Scanning electron microscopy (SEM) was used to analyze the microstructure of fabricated composite. Experimental work was executed as per the L9(33) orthogonal array design by considering three input machining parameters like pulse current (Ip), pulse on-time (Ton) and pulse off-time (Toff), respectively. The material removal rate (MRR) and surface roughness (SR) were chosen as the output responses for machining of the developed composite. The signal-to-noise (S/N) ratio was employed to determine the optimum levels of machining parameters for the output responses. Moreover, analysis of variance (ANOVA) was used to find the significant contribution of parameters. The main effect plot explored that Ip of 25 A, Ton of 115μs and Toff of 60μs were identified as the optimum levels of machining parameters which provide the maximum MRR (0.36757g/min) and minimum SR (3.826μm) for the proposed composite during the WEDM process. ANOVA results revealed that Ip was the most dominant factor regarding MRR and SR followed by Ton with contributions of 74.05% and 14.48%, respectively.

Keywords: Al7075 alloy; ZrO2; stir casting; composite; WEDM parameters; Taguchi method; TOPSIS method; ANOVA (search for similar items in EconPapers)
Date: 2022
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DOI: 10.1142/S0218625X22500081

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