Experimental investigation and statistical modelling of cutting speed in AL6063-W composite by wire EDM process

In the present work experimental investigations were performed on a novel aluminium-tungsten metal matrix (AL6063-W), in order to study the influence of machining parameters on responses like cutting speed and surface roughness. The composite was prepared by the stir casting process, and experiments were carried out on commercially available wire electrical discharge machine (WEDM). In the preliminary experiments, it was observed that Pulse on time (Ton), pulse off time (Toff) and servo voltage (Sv) plays a significant role in effecting the cutting speed and surface roughness. Further, response surface methodology (RSM) was used to develop the statistical model to predict the cutting speed in WEDM process. Central composite design (CCD) technique was used to design a set of 20 experiments and analysis of variance (ANOVA) technique at a confidence interval of 95% (p = 0.05) was used to develop the statistical model. It was found that among the various parameters Ton plays a significant role (78%) in influencing the cutting speed during machining, followed by Sv (8.3%) and Toff (7%). Further, Genetic algorithm (GA) technique was applied to determine the optimized parameters. Copyright (c) 2022 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International Conference on Recent Advances in Modeling and Simulations Techniques in Engineering and Science.