Multi-Objective Optimization in Wire-Cut Electric Discharge Machining of Al 6063/Al2O3 Metal Matrix Composite through Response Surface Methodology

This paper proposed a response surface methodology technique to optimize the multi-response of wire-cut electric discharge machining process. The machining was done on Al 6063 plate is casted with varying mass of Al2O3 (3%, 6%, 9%). Stir casting process is adopted for casting the composite plate. Design Expert is used to identify the effect of key operating factors on output measures such as surface finish and kerf by using Pulse on-time, pulse off-time, servo feed and varying mass of Al2O3 (3%, 6%, 9%). Also the distribution of Alumina and Aluminium is examined by microstructure analysis, and the material is tested for its mechanical Properties such as tensile strength and Hardness. We found that with respect to increase in pulse on-time and weight percentage of alumina the Surface roughness and kerf decreased leaving a better finish. Also a comparison has been done between the result obtained through response surface methodology and experimental values which indicates that the experimental values are very much close to the predicted values.