Parameter optimization for wire-cut electrical discharge machining of stir cast AA6063 alloy/SiC (black and green) using Taguchi method with grey relational analysis

R Raj Kumar; Gnana Prasanna; G S Hikku

doi:10.2478/msp-2022-0011

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Parameter optimization for wire-cut electrical discharge machining of stir cast AA6063 alloy/SiC (black and green) using Taguchi method with grey relational analysis

Materials Science-Poland

Volume 40 (2022): Issue 1 (March 2022)

By: R Raj Kumar, Gnana Prasanna and G S Hikku

Open Access

|Jun 2022

Figures & Tables

Table 1

Input machining parameters for both AA6063/SiC_g and AA6063/SiC_b composites and their levels

Factor	Symbol	Units	Level
Factor	Symbol	Units	Level 1	Level 2	Level 3
Pulse on time	T_ON	μs	50	75	100
Wire Feed	WF	m/min	6	12	18
Flushing Pressure	FP	MPa	1	2	3

Table 2

Experimental design for L9 orthogonal array and the experimental data

Sl. no.	T_ON	WF	FP	AA6063/SiC_b		AA6063/SiC_g
Sl. no.	T_ON	WF	FP	MRR-1 (mm³/min)	R_a-1 (μm)	MRR-2 (mm³/min)	R_a-2 (μm)
1	50	6	1	8.57	1.88	8.81	1.82
2	50	12	2	9.09	1.59	9.27	1.63
3	50	18	3	9.78	1.11	9.94	1.24
4	75	6	2	10.51	1.65	10.83	1.69
5	75	12	3	11.23	1.67	11.19	1.81
6	75	18	1	11.86	2.45	11.98	2.40
7	100	6	3	13.25	2.56	13.05	2.72
8	100	12	1	13.52	3.09	13.66	3.05
9	100	18	2	13.61	3.10	14.13	3.17

[i] MRR-1 and R_a-1 = MRR and surface roughness of AA6063/SiC_b; MRR-2 and R_a-2 = MRR and surface roughness of AA6063/SiC_g.

[ii] All the experiments were conducted thrice, and the average values are provided.

[iii] FP, flushing pressure; MRR, material removal rate; T_ON, pulse on time; WF, wire feed.

XRD patterns of **(A)** SiC_b, **(B)** SiC_g, and **(C)** AA6063. XRD, X-ray diffraction

SEM images of **(A)** SiC_b and **(B)** SiC_g. SEM, scanning electron microscopy

Influence of the input factors on the S/N ratio of **(A)** MRR-1, **(B)** *R_a*-1, **(C)** MRR-2, and **(D)** R_a-2. MRR-1, material removal rate; R_a, surface roughness; S/N, signal-to-noise

Table 3

ANOVA for MRR-1, R_a-1, MRR-2, and R_a-2

Response	Source	DF	Adj. SS	F-value	P-value
MRR-1 R² = 99.65%	T_ON	2	27.9286	268.49	0.004
	WF	2	1.4216	13.67	0.068
	FP	2	0.1940	1.87	0.349
Error	2	0.1040
Total	8	29.6483
R_a-1 R² = 96.64%	T_ON	2	3.07616	22.98	0.042
	WF	2	0.05429	0.41	0.712
	FP	2	0.72142	5.39	0.157
Error	2	0.13389
Total	8	3.98576
MRR-2 R² = 97.82%	T_ON	2	27.4332	1818.10	0.001
	WF	2	1.8955	125.62	0.008
	FP	2	0.0138	0.91	0.523
Error	2	0.0151
Total	8	29.3575
R_a-2 R² = 96.26%	T_ON	2	3.19647	22.69	0.042
	WF	2	0.05627	0.40	0.715
	FP	2	0.37520	2.66	0.273
Error	2	0.14087
Total	8	3.76880

[i] Adj., adjusted; ANOVA, analysis of variance; DF, degrees of freedom; F, F-ratio; FP, flushing pressure; MRR-1, material removal rate-1; P, probability; R_a, surface roughness; SS, sums of squares; T_ON, pulse on time; WF, wire feed.

Table 4

Grey relational analysis for the WEDM process of AA6063/SiC_b

Experimental data		Normalized data		Grey relational coefficients		GRG-1	Rank
MRR-1	R_a-1	MRR-1	R_a-1	MRR-1	R_a-1	GRG-1	Rank
8.57	1.88	0	0.613	0.333	0.564	0.449	9
9.09	1.59	0.103	0.759	0.358	0.675	0.516	7
9.78	1.11	0.240	1.000	0.397	1.000	0.698	1
10.51	1.65	0.385	0.729	0.448	0.648	0.548	6
11.23	1.67	0.528	0.719	0.514	0.640	0.577	5
11.86	2.45	0.653	0.327	0.590	0.426	0.508	8
13.25	2.56	0.929	0.271	0.875	0.407	0.641	4
13.52	3.09	0.982	0.005	0.966	0.334	0.650	3
13.61	3.10	1.000	0.000	1.000	0.333	0.667	2

[i] GRG, grey relational grade; MRR-1, material removal rate-1; R_a, surface roughness; WEDM, wire-cut electrical discharge machining.

Table 5

Grey relational analysis for the WEDM process of AA6063/SiC_g

Experimental data		Normalized data		Grey relational coefficients		GRG-1	Rank
MRR-2	R_a-2	MRR-2	R_a-2	MRR-2	R_a-2	GRG-1	Rank
8.81	1.82	0	0.699	0.333	0.625	0.479	9
9.27	1.63	0.086	0.798	0.354	0.712	0.533	7
9.94	1.24	0.212	1.000	0.388	1.000	0.694	1
10.83	1.69	0.379	0.767	0.446	0.682	0.564	4
11.19	1.81	0.447	0.705	0.475	0.629	0.552	6
11.98	2.40	0.596	0.399	0.553	0.454	0.504	8
13.05	2.72	0.797	0.233	0.711	0.395	0.553	5
13.66	3.05	0.912	0.062	0.850	0.348	0.599	3
14.13	3.17	1.000	0.000	1.000	0.333	0.667	2

[i] GRG, grey relational grade; MRR-2, material removal rate-2; R_a, surface roughness; WEDM, wire-cut electrical discharge machining

SEM micrographs of WEDM-processed surfaces: **(A, B)** AA6063/SiC_b and **(C, D)** AA6063/SiC_g. SEM, scanning electron microscopy; WEDM, wire-cut electrical discharge machining

Texture analysis from Figure 4B (i–iii) and Figure 4D (iv–vi) at three different positions using Gwyddion image processing software (the red arrow denotes the 100-count mark)

EDX mapping analysis over the machined surface of AA6063/SiC_b. EDX, energy dispersive X-ray spectroscopy; C, carbon; O, oxygen; Mg, magnesium; Al, aluminium; Si, silicon

EDX mapping analysis over the machined surface of AA6063/SiC_g. EDX, energy dispersive X-ray spectroscopy; C, carbon; O, oxygen; Mg, magnesium; Al, aluminium; Si, silicon

SEM micrograph of debris generated from **(A and B)** AA6063/SiC_b and **(C and D)** AA6063/SiC_g. EDX analysis of debris generated from **(E)** AA6063/SiC_b and **(F)** AA6063/SiC_g. EDX, energy dispersive X-ray spectroscopy; SEM, scanning electron microscopy

Experimental vs predicted values for **(A)** MRR-1, **(B)** *R_a*-1, **(C)** MRR-2, and **(D)** *R_a*-2. MRR, material removal rate; *R_a*, surface roughness

References

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DOI: https://doi.org/10.2478/msp-2022-0011 | Journal eISSN: 2083-134X (formerly 2083-124X) | Journal ISSN: 2083-1331

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Language: English

Page range: 68 - 83

Submitted on: Nov 13, 2021

Accepted on: Apr 11, 2022

Published on: Jun 18, 2022

Published by: Wroclaw University of Science and Technology

In partnership with: Paradigm Publishing Services

Keywords:

AA6063,

silicon carbide,

wire-cut electrical discharge machining,

stir cast,

Taguchi method,

grey relational analysis

Related subjects:

Materials sciences,

Materials sciences, other,

Nanomaterials,

Functional and smart materials,

Materials characterization and properties

© 2022 R Raj Kumar, Gnana Prasanna, G S Hikku, published by Wroclaw University of Science and Technology
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 License.

Volume 40 (2022): Issue 1 (March 2022)

Parameter optimization for wire-cut electrical discharge machining of stir cast AA6063 alloy/SiC (black and green) using Taguchi method with grey relational analysis

Figures & Tables

Table 1

Table 2

Fig. 1

Fig. 2

Fig. 3

Table 3

Table 4

Table 5

Fig. 4

Fig. 5

Fig. 6

Fig. 7

Fig. 8

Fig. S1

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