Modeling and Optimization of EDM of Al 7075/10wt% Al<sub>2</sub>O<sub>3</sub> Metal Matrix Composites by Response Surface Method

Abstract

The newly engineered metal matrix composite (MMC) of aluminium 7075 reinforced with 10 wt% of Al2O3 particles were prepared by stir casting method. Electrical discharge machining (EDM) was employed to machine MMC with copper electrode. The experiment plan adopts face centered central composite design of response surface methodology. Analysis of variance was applied to investigate the influence of process parameters and their interactions viz., pulse current, gap voltage, pulse on time and pulse off time on material removal rate (MRR), electrode wear ratio (EWR) and surface roughness (SR). The objective was to identify the significant process parameters that affect the output characteristics. Further a mathematical model has been formulated by applying response surface method in order to estimate the machining characteristics such as MRR, EWR and SR.