FROM SPARKS TO PRECISION: PARAMETRIC OPTIMIZATION OF WIRE EDM FOR EFFICIENCY AND ACCURACY IN AL 6113 ALLOY MACHINING
DOI:
https://doi.org/10.55766/sujst11362Keywords:
Al 6113 alloy, Kerf width, Material removal, Microstructure, Peak Current, Pulse on time, Wire-EDMAbstract
Wire-Electro Discharge Machining (WEDM) is a promising non-traditional machining process for aluminium alloys, which are otherwise difficult to machine using conventional methods due to plastic deformation and the formation of heat-affected zones. In the present study, the machinability of Al 6113 alloy was investigated under varying WEDM parameters using a Taguchi L9 orthogonal design. The influence of pulse-on time, pulse-off time, and peak current on material removal rate (MRR), kerf width, and surface morphology was systematically evaluated. The results indicate that pulse-on time is the most significant factor influencing both MRR and kerf width, while pulse-off time also plays a critical role in determining machining efficiency. Surface morphology analysis revealed that higher discharge energy conditions led to the formation of microcraters, micropores, and recast layers, whereas optimized parameters improved surface integrity. In addition, a Pareto front-based multi-objective optimization was employed to balance MRR and kerf width, identifying non-dominated solutions and a knee point for improved trade-offs between productivity and machining accuracy. The findings highlight the effectiveness of WEDM in machining Al 6113 alloy and establish its potential for precision applications in aerospace and automotive industries.
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