In the highly demanding domain of advanced technologies, Wire Electro Discharge
Machining (EDM) has distinguished itself as one of the most promising methods
for the efficient machining of sophisticated composite materials. As a critical
advanced machining process, EDM caters to the stringent requirements for
intricate geometries and effective material removal. This study focuses on
Al6063 Alloy Composites reinforced with Silicon Carbide and Fly Ash, materials
celebrated for their high strength, exceptional oxidation-corrosion resistance,
and high-temperature performance. These composites are widely applied across
aerospace, marine, automotive industries, nuclear power, and oilfield sectors.
The current research involves a rigorous experimental analysis and parametric
optimization of the aluminum matrix composite utilizing EDM. The primary
objective is to fine-tune the process parameters, including pulse-off time,
current, and taper angle. The experiments were designed and conducted using
Taguchi’s Orthogonal Array to ascertain the optimal parametric settings for
critical responses such as Surface Roughness (SR) and Material Removal Rate
(MRR). Analysis of variance (ANOVA) results reveal that pulse-off time exerts
the most significant influence on MRR, followed by current and taper angle.
While pulse-off time also has the greatest effect on SR, followed by taper angle
and current. The developed regression models and optimized parameter values for
workpieces with various taper angles of Al6063 composite can be effectively
applied in the industry to boost productivity and achieve superior performance
outcomes.