Effect of Wire EDM Process Parameters on Machining of Aluminium Matrix Composites (356/Fly Ash)

Aluminium matrix composites (AMCs) of 3, 6 and 9% fly ash as reinforcement and aluminium cast alloy (356) as matrix were fabricated using stir casting technique. The effects of wire EDM process parameters on machining of AMCs were investigated using Grey relational analysis. In this study, the input machining parameters such as gap voltage, pulse on time, pulse off time, wire feed and reinforcement percentage are optimized with considerations of multiple performance characteristics of the output parameters of MRR and SR. Optimal process parameters were selected based on Grey relational grades and confirmation experiments were conducted. ANOVA was used to find the contribution of each machining parameter. The results show that pulse on time has the most significant effect for achieving maximum GRG and is followed by gap voltage, wire feed, pulse off time and reinforcement in that order. The WEDM process was improved through this approach.