Evaluation of Wire Electrical Discharge Machining Performance Features on EN AW-6082 T6 Aluminum Alloy and Optimization of Machining Characteristics

Wire electrical discharge machining (WEDM) has become the most important advanced production technology compared to other methods. The major goal of the current experiment is to use WEDM to ascertain the machining characteristics of the aluminum alloy EN AW-6082 T6, which has better corrosion resistance. The trials were planned using the design of experiments-response surface methodology. In total, 32 sWEDM experiments with molybdenum wire were conducted. The methods were used to reduce surface roughness (SR) and dimensional deviation (DD) by influencing machining parameters such as pulse on time (T-on), pulse off time (T-off), spark gap voltage (GV), peak current, and wire tension to help industrialists manufacture cost-effective industrial components. After machining, the significance of each parameter was determined using an analysis of variance (ANOVA), which revealed that for SR, T-on is the influencing factor and for DD, GV is the dominant factor. The measured output was optimized using desirability function analysis. The confirmatory tests were carried out, which indicate that the desired consistency with individual parameters was achieved, ensuring the validity of this investigation.