Investigating the influence of WEDM process parameters in machining of hybrid aluminum composites

Amresh Kumar, Neelkant Grover, Alakesh Manna, Jasgurpreet Singh Chohan, Raman Kumar, Sunpreet Singh, Chander Prakash, Catalin Iulian Pruncu

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This article presents an experimental investigation to assess the influence of input process parameters of machinability of wire electrical discharge machining (WEDM) process for machining of triple-reinforced silicon carbide, graphite, and iron oxide hybrid aluminum (Al-6061) metal matrix composites. The composite work specimens, developed using stir casting process, have been processed through WEDM process by adopting a statistically controlled design of experimentation approach. Furthermore, analysis of variance and regression analysis have been performed to understand the influence of the input process parameters on material removal rate (MRR) and spark gap (SG) width. The statistical analysis highlighted the improvements in MRR and SG by 33.72% and 27.28%, respectively, upon adopting the suggested optimized range of input process parameters. Further, the morphology of the machined composite surfaces has also been studied using scanning electron microscopy and energy dispersive spectroscopy to report the phenomenon of formation of recast layer.

Original languageEnglish
Pages (from-to)1-14
Number of pages14
JournalAdvanced Composites Letters
Early online date15 Oct 2020
Publication statusE-pub ahead of print - 15 Oct 2020


  • aluminum composites
  • optimization
  • recast layer
  • regression analysis
  • wire EDM

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