Study the Effect of Machining Process Parameters on Die-Sinking EDM for Al5083/B4C Composite

Abstract

The study mostly emphasizes on selecting the best machining parameters among the conducted experiments and evaluating the optimal machining parameters for Al5083/10wt%B₄C (boron carbide) composite in electro discharge machine (EDM). The paper is an integration of equally weighted experimental and computational study. In the experimental part of the study, specimen of Al5083/10wt%B₄C is prepared by the popular ex-situ technique in an induction furnace through stir casting process.The experimental part includes design of experiment by Taguchi’s method, performing the experimentation for the different machining combinations and finally measuring of performance parameters The computational part of the study is the formulation of predictive model using soft computing techniques like response surface methodology (RSM), Taguchi and multi-variate regression analysis (MVA). The performance of the three techniques were scrutinised on a statistical platform and model formulated by RSM emerged as the best. The developed model is less than 5% error. The output values show that input process parameters has significant influenced on material removal rate and surface roughness.