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

Abstract The present investigation aimed to determine the optimal parameters for wire-cut electrical discharge machining (WEDM) stir cast aluminum alloy AA6063 at 850°C reinforced with 10 wt.% green SiC (SiC g ) and black b particles. WEDM parameters, such as pulse on time ( T ON ), wire feed (WF) rate, flushing pressure (FP) of resultant AA6063/SiC composites, were optimized using Taguchi method L9 orthogonal array estimate responses, surface roughness metal removal rate. Further, through grey relational analysis, finest composites evaluated = 50 μs, WF rate 18 m/min, FP 3 MPa. With optimum obtained, conformational experiments conducted, scanning electron microscopic images recorded, along energy-dispersive X-ray (EDX) spectroscopic data worn surfaces debris. From EDX mapping machined surface, it was evident that displays a more polished than . However, applications requiring high better results