Development of semi empirical model on material removal rate in WEDM process for aluminium metal matrix material using dimensional analysis

Abstract

Wire electrical discharge machining is a non-conventional process for manufacturing complicated and intricate parts. In this paper, dimensional analysis and nonlinear estimation method Quassi Newton was used to established semi empirical model for various aluminium metal matrix material considering pulse on time, wire diameter, peak current and various materials properties likes density, thermal conductivity, electrical conductivity, specific heat capacity, coefficient of thermal expansion, melting temperature, and latent heat of fusion as model parameter. Taguchi L27 orthogonal array were used to perform the experiment for aluminium metal matrix. Semi empirical model shows more than 99% prediction than experiment data. Constant and power indices value of model shows wire diameter, peak current, pulse on time and work material properties such as thermal expansion of coefficient and melting point temperature are significant parameters for material removal rate. [Submitted 26 August 2017; Accepted 2 April 2018]