WEDM Performance Analysis of Al/Gr MMC using Response Surface Method

Aluminum (Al) Graphite (Gr) composite is made with powder formed Graphite with different compositions of Gr (5%, 10%, 15%, 20%). Wire EDM process is carried out on it & different performance parameters such as surface roughness, material removal rate and the kerf width have been evaluated using response surface method (RSM).e Method. Non-destructive testing of different compositions is carried out to check their microstructures and the most effective composition for this composite is determined. Wire Electrical-discharge wire cutting is basically a variation of an EDM process in which a slowly moving wire travels along a prescribed path, cutting the workpiece, by discharge sparks which occurs in a small gap between wire & workpiece and removes unwanted material from parent metal by melting & vaporization. WEDM process is carried out on the different compositions of AlGr plates. During EDM different combinations of parameters of machining such as Toff, Ton, current, Wire feed rate are applied to these combinations. After EDM the experimental values of Ra, MRR and Kerf are determined. The mathematical model has constructed using Minitab software.