Effects of Wire EDM Machining Variables on Material Removal Rate and Surface Roughness of Al 6061 Alloy

Wire Electrical Discharge Machining (WEDM) is one of the fastest extensive growing processes in nontraditional machining. So broad are its capabilities that it can encompass the production, aerospace/aircraft, nuclear reactor, medical industries, and virtually all areas of conductive material machining. But low material removal rate and high surface roughness in the WEDM process are the most difficult problems in practical application. Analysis of the effect and the optimization of cutting parameters on material removal rate and surface roughness in the WEDM of Al 6061 t6 alloy have been made in the present paper. Experimental investigation based on Response Surface Methodology (RSM) has been carried out to optimize the main process parameters like pulse on time, pulse off time, wire feed rate, and gap voltage. Experimental validation of the proposed models shows that the desired Material Removal Rate (MRR) and surface roughness (Ra) can be achieved by adjustment of cutting parameters.