Optimization of WEDM process parameters by RSM in machining of stir cum squeeze cast A413–B4C composites

Abstract

In this paper, aluminium alloy metal matrix composites were manufactured via stir cum squeeze casting technique owing to their tremendous automotive and aviation applications. The aluminium alloy with 12 weight percentage boron carbide (A413 with 12 wt% B4C) composites was prepared with optimal stir cum squeeze casting parameters like applied squeeze pressure of 140 MPa, 225 °C preheated die temperature and 12 wt% of B4C particles which yielded pore-free fine-grained equally distributed ceramic particles of the composite, leading to an enhanced higher hardness of 136 VHN and higher tensile value of 373 MPa due to squeezing pressure and B4C particles. The prime intern of the wire electrical discharge machining process was adopted for investigating the machinability of stir cum squeeze cast high-strength A413 with 12 wt% B4C composite. The stratagem of response surface methodology along through central composite rotatable design was taken towards systematic design of experiments. The experimental study results exhibited a possibility of higher amount of metal removal rate for maximum pulse on-time and peak current values, and also better surface roughness was acquired for higher values of pulse off time. The mathematical model shows excellent prediction in accordance with experimental data which seems to fall inside the bounds of acceptable average error around 6.47% and 1.52% for metal removal rate and surface roughness through additivity tests, respectively. The proposed multi-response optimization results revealed a great potential for improving machined surface quality which could be utilized according to the industrial requirements.