Optimization of Machining Parameters for Wire EDM of AMCs (LM5/ZrO2) using Taguchi Technique

Abstract

Aluminium alloy with high toughness, hardness, and impact resistance, is increasingly in demand in the aerospace and mechanical industries. Machine tools have seen rapid growth over the past two decades, but they are still not commonly used to their maximum potential. The inability to use machine tools at their peak output thresholds is at the core of the problem. Practicing engineers and researchers were intrigued by the difficulty of reaching a meticulous analysis of effective parameters. AMCs-LM5/3,6,9% ZrO2 fabricated by stir casting process are machined in Wire EDM to choose the optimum parameters by changing the Pulse on Time, Pulse off Time, Gap Voltage and Wire Feed. Achieving a good surface finish, as well as a better MRR and less kerf in the WEDM machining is of paramount importance. The experiments were conceded using the Taguchi’s L27 OA to obtain the desired effects. ANOVA determines the parameters that affect the Wire EDM, and also the relative contribution of machining parameters. The optimum levels of process parameters, for maximum MRR, minimum SR and minimum kerf were calculated. S/N ratio analysis determines the parameter that has the most impact on the response. A confirmation experiment was done for the best combination of parameters.

Keywords

• amcs
• taguchi technique
• wire edm
• anova & s/n ratio