Dielectric Fluid Parameter Optimization in Machining of Composite Material using WEDM Process

Wire Electric Discharge Machining (WEDM) has become most popular among the non-conventional machining processes because of precise machining and accuracy of parts. The process is preferable for accurate machining of complex geometries in hard materials such as Aluminium Silicon Carbide metal matrix composite. In this work, an attempt is made to analyze and optimize the dielectric fluid parameters in machining of Al/SiCp 10% work material. The input variables such as volume flow rate, flow velocity and chemical composition of dielectric medium used in the WEDM are chosen for this. Taguchi's L9 orthogonal array is used to conduct experiments in WEDM machine and ANOVA results have confirmed the influence of chosen parameters on the output responses. Computer simulation model of the WEDM tank with dielectric fluid, work piece and nozzle is presented using Fluent software. The Fluent model is analyzed based on the maximum removal of debris in the work material. Optimization is carried out to maximize the Material Removal Rate (MRR) and minimize surface roughness. The results obtained from Taguchi's optimization and Fluent analysis have been validated by carrying out tests on WEDM. The study shows that volume flow rate and flow pressure can adequately influence MRR and surface roughness.