Effect of Al7075 and activated carbon reinforced composite on optimizing WEDM responses

This paper presents wire cut electrical discharge machining (WEDM) response characteristics of Aluminium 7075 (Al7075) reinforced with powdered activated carbon (PAC) composite. In recent days WEDM has become a significant machining process in targeting its benefits of contributing improved material removal rate (MRR) and low surface roughness (SR). This is due the rising need for intricate, accurate, and superior structural components, the WEDM process emerges as a formidable alternative to traditional machine tools. In this work Pulse-on time (Ton), pulse-off time (Toff), discharge current (IA) and servo speed rate (SS) are the variables to be given as input and machining responses such as MRR and SR are studied. From Analysis of Variance (ANOVA) study it is found that discharge current and servo speed is the significant parameters. The optimal desirability condition is obtained with input parameters Ip: 2000 mA; Ton: 8.9 μs; Toff: 25 μs and SS: 150 rpm for the precision machining. The optimum response parameters are found as MRR 10.46 mm³/min and SR 3.32 μm. Results shows that the model designed for the prediction of MRR produces an above 98.27% and the prediction of SR is above 97.17%. The error percentage among the experimental and predicted MRR and SR were estimated. Additionally confirmatory test is performed with optimal results achieved from response surface methodology (RSM) and desirability technique. Metallurgical tests like electron backscatter diffraction analysis (EBSD) and microstructure are conducted to confirm the surface properties and atomic force morphology (AFM) analysis is applied to clarify the structural features of machined composites. The results revealed that the variation of hard deflection is caused by depression of eroded materials on the top layers of machined surface.