Optimization of Micro-WEDM Process of Aluminum Matrix Composite (A413-B₄C): A Response Surface Approach

Abstract

This article presents a systematic approach for modeling and analysis of machining characteristics of Micro-Wire Electric Discharge Machining (Micro-WEDM) process using the Response Surface Methodology (RSM). The effect of various input parameters, such as voltage, capacitance, and feed rate on machining, performance of material removal rate (MRR), kerf width (KW), and surface roughness (SR) was investigated. Experimental work was carried out on Aluminum Matrix Composite (A413-9% B4C) with zinc coated copper wire using RSM with central composite design (CCD). The second order mathematical modeling and analysis of variance (ANOVA) were performed to optimize the machining parameters. It has been found out that main and interaction effects are significant on the machining performance. The optimized values of MMR, KW, and SR parameters were found to be 0.259943 mm3/min, 87 µm, and 0.97 µm, respectively.