Synthesis and Characterization of Mechanical Properties and Wire Cut EDM Process Parameters Analysis in AZ61 Magnesium Alloy + B4C + SiC

Abstract

Wire Cut Electric Discharge Machining (WCEDM) is a novel method for machining different materials with application of electrical energy by the movement of wire electrode. For this work, an AZ61 magnesium alloy with reinforcement of boron carbide and silicon carbide in different percentage levels was used and a plate was formed through stir casting technique. The process parameters of the stir casting process are namely reinforcement %, stirring speed, time of stirring, and process temperature. The specimens were removed from the casted AZ61 magnesium alloy composites through the Wire Cut Electric Discharge Machining (WCEDM) process, the material removal rate and surface roughness vales were carried out creatively. L 16 orthogonal array (OA) was used for this work to find the material removal rate (MRR) and surface roughness. The process parameters of WCEDM are pulse on time (105, 110, 115 and 120 µs), pulse off time (40, 50, 60 and 70 µs), wire feed rate (2, 4, 6 and 8 m/min), and current (3, 6, 9 and 12 Amps). Further, this study aimed to estimate the maximum ultimate tensile strength and micro hardness of the reinforced composites using the Taguchi route.