Optimising EDM Process Parameters for Aged AA2024/B4C Metal Matrix Composites: Enhancing Mechanical Properties and Machining Efficiency

Abstract

Optimising the process parameters is essential when working with aged AA2024 Metal Matrix Composites (AAMMCs) due to their significant impact on mechanical characteristics, tool wear, accuracy, surface quality, integrity, precision, consistency, stability and cost-effectiveness. Boron Carbide (B₄C) was selected as the reinforcing material because of its exceptional mechanical characteristics. AA2024/B4C (0%, 5%, 10%, 15% and 20% wt.) samples were manufactured using the stir-cast method. This AA2024/15% wt. B₄C MMC was aged in a furnace at 520°C for 180 minutes before being chilled. The tensile and compressive strengths of both the old and non-aged AAMMCs were measured using a universal testing machine and a compression testing machine, respectively. To find the best mix of manufactured AAMMCs, we looked at their mechanical characteristics. It was determined that AA2024/15% wt. B4C AAMMC was the best combination because it had higher values for tensile strength and compressive strength than the others. Electrical Discharge Machining (EDM) parameters were determined using Taguchi L9 orthogonal array, in accordance with the central composite design and Combined Compromise Solution (CoCoSo) as its basis, the optimisation module managed the process limitations. Current (Z), pulse-on time (Y) and chromium concentration (X) were selected for optimisation. The optimisation response parameters chosen were Surface Roughness (SR) and Tool Wear Rate (TWR). Input parameters for EDM are influenced by X, Y and Z in that order. The optimised EDM parameters were found as 0.324 TWR and 3.76 SR, with a chromium concentration of 10 g/l, a current of 6A and a pulse on time of 260 µs.