Desirability-Based Multi-objective Optimization and Analysis of WEDM Characteristics of Aluminium (6082)/Tungsten Carbide Composites

Wire electrical discharge machining is a broadly recognized unconventional machining process capable of accurately manufacturing rigid components with compound contours. The present study is to optimize the machining parameters of Al (6082)/tungsten carbide composite. Peak current, pulse-on time, pulse-off time, wire feed rate and tungsten carbide percentage were used as variables to study the material removal rate and surface roughness. Analysis of variance technique is used to study the effect on material removal rate and surface roughness. Material removal rate is primarily influenced by % tungsten carbide followed by peak current, pulse-off time, feed rate and pulse-on time, respectively. Surface roughness is highly influenced by peak current followed by % tungsten carbide, pulse-off time, pulse-on time and feed rate respectively. Scanning electron microscopic structures of the machined surfaces were characterized by the presence of hillocks, fine and deep craters, microcracks, protrusion, recast layers and debris. Desirability-based multi-objective optimization was employed to optimize the process parameters. The developed mathematical model has a good level of adequacy and can be used to predict the responses with minimum error. The experimental results along with the mathematical model and optimization will serve as a technical database for aerospace, automotive, military and commercial applications.