Surface Veracity Investigation for the WireEDM of Al/ZrO2(P)-MMC

This paper presents investigation of surface veracity of WireEDM surface of Al/ZrO2(P)-MMC. The optimal set of process parameters for WireEDM of considered MMC are obtained using response surface methodology (RSM) for maximum MRR and minimum SR (Ra). In the present paper, surface veracity aspects that include composition, surface defects, and thickness of recast layer are investigated for the machined surfaces which are obtained from the set of optimal process parameters. From the investigation, it can safely be concluded that for the WireEDM of of Al/ZrO2(P)-MMCs, lower parameter setting values of PW and SPT along with higher parameter setting value of TBP are desirable from the viewpoint of good surface finish and surface topography of the machined surfaces, however, higher parameter setting values of PW and SPT along with lower parameter setting value of TBP are desirable from the viewpoint of good material removal rate but surface topography of the machined surfaces contains more micro-cracks, porosity, and deep craters. Further, there is transfer of Cu and Zn ions from diffused wire electrode to the obtained surface.