Performance optimization of wedm Process parameters on aluminium 6061 Metal matrix composite

Abstract

Wire Electric Discharge Machining (WEDM) process is a Non-Traditional Machining Process (NTMP) for machining of high strength materials, super alloys and Metal Matrix Composites (MMCs). MMC materials are getting hold of significance in the recent decade due to their mechanical property advantages.The applications of MMCs are expanded to various fields such as automobile, aerospace and components manufacturing industries. There are many fabrication methods are avilable to produce the Aluminium Metal Matrix Composites (AMMCs)ie., stir casting, powder metallurgy and squeeze casting. Among these, stir-casting method is aneconomical, easy to handle and suitable for mass production. In the present research, the AMMCs are fabricated by using AA6061 alloy reinforced with various wt % of Al2O3 like 6 % and 8% through stir casting process and cut into suitable size, for testing and machining in WEDM.The prepared AMMCs specimens are subjected to the mechanical testing as per the ASTM standard for tensile, compressive, wear and hardness. Based on the testing the following results are observed in the sequence of 6 and 8 wt% of reinforced composite materials. The tensile strength of the AMMCs is 129 N/mm2 and 140 N/mm2, compressive strength of the AMMCs is 384N/mm2 and 419N/mm2, coefficient of friction of AMMCs is 0.22 and 0.37 and the hardness of the AMMCs is 51.72HV and 52.86HV.The prepared AMMCs specimens are subjected to the machining through WEDM. The dimension of the workpiece considered for the machining is 100 x100 x10 mm. A brass wire is used as tool electrode material newline