Parameter optimization of cnc wire cut edm process for machining Aluminium 6063 b4c metal matrix composites

Abstract

Among various types of composite materials, metal matrix composites are used for wide applications in Aerospace, Automobile, Defense, Nuclear power plant, Electronics, Bio-medical, Sporting industries and Fluid flow. Aluminium Metal Matrix Composites (AMMCs) are preferred for their superior properties such as high strength-to-weight ratio, high toughness, high specific strength, good wear resistance and low thermal expansion co efficiency. In this research Boron Carbide (B4C) ceramic particles are used as reinforcement material in Aluminium6063 matrix. Stir casting method is selected to prepare the AMMCs as it is simple and effective method for dispersion. Three different volume percentage compositions of reinforcements 3%, 6% and 9% are chosen. This work is focused on the preparation of AMMCs with (B4C) reinforcement in particle form and to find the effect of percentage compositions of B4C on CNC-wire cut electrical discharge machining (WEDM). The micro structural features of AMMCs are evaluated using a Scanning Electron Microscope (SEM) and Energy Dispersive X-ray Analysis (EDAX). newlineThe CNC WEDM is one of the non conventional machining processes which is used to cut all electrical conducting materials, especially for cutting high hard materials and complicated profile shapes. The principle of machining process is erosion of metal by electrical and thermal processes. The working parameters of WEDM such as servo voltage (SV), Pulse on-time (Ton), Pulse off-time (Toff), Wire tension (WT), and Wire speed (WS) are influencing the machining performance measures namely Metal removal rate (MRR), Surface roughness (SR) and Kerf width (KW). Further an experimental study is conducted to find optimum process parameters such as servo voltage, pulse on newline