Published Paper Details:

Wire Electrical Discharge Machining (EDM) has emerged as a prominent machining process due to its capability to fabricate intricate shapes on conductive materials with high precision. This research focuses on investigating the machinability of Aluminum Alloy 6061 using Wire EDM and optimizing the process parameters to enhance machining efficiency and surface quality. The study begins with a comprehensive analysis of the machinability characteristics of Aluminum Alloy 6061, including its mechanical properties, thermal conductivity, and electrical conductivity. Experimental trials are conducted to evaluate the influence of key process parameters such as pulse-on time, pulse-off time, wire tension, and flushing conditions on material removal rate (MRR), tool wear rate (TWR), and surface roughness. Through systematic experimentation and statistical analysis, optimal process parameters are determined to maximize MRR while minimizing TWR and surface roughness. Advanced techniques such as response surface methodology (RSM) and Taguchi method are employed to establish mathematical models correlating process parameters with machining performance indicators. Furthermore, the study explores the effects of different dielectric fluids, electrode materials, and wire diameters on machining characteristics to identify the most suitable combinations for achieving superior machining outcomes. Additionally, the environmental impact and economic feasibility of the optimized Wire EDM process are assessed. The findings of this research contribute to enhancing the understanding of Wire EDM of Aluminum Alloy 6061 and provide practical insights for optimizing the machining process in industrial applications. By improving machining efficiency and surface quality, the proposed methodology can potentially lead to significant advancements in the manufacturing of precision components using Aluminum Alloy 6061.