Optimization of Process Parameters of Taper Cutting by WEDM Process of Al-SiC-ZrO2 Composite

Abstract

Wire Electric Discharge Machining (WEDM) is a precise machining method widely used for cutting intricate geometries in conductive materials. The present study investigates taper WEDM cutting of Al-SiC-ZrO₂ composite material using three input parameters such as taper angle (TA), pulse-on time (T_ON), and peak current (I_P) and their effects on machining response,angular error (AE), and cutting rate (CR). Further, the Taguchimethod with L₉ orthogonal arrayemployed to design experiments efficiently. further, ANOVA and regression modeling were applied to analyze parameter impact, while multi-objective optimization was performed to determine feasible parameter sets. Results show that theTA and T_ON strongly influence AE, while I_P governs surface roughness and productivity. Optimized parameters provide improved dimensional accuracy and machining efficiency, making WEDM more reliable for Al-SiC-ZrO₂ composite applications in aerospace and automotive industries. Further SEM analysis revealed that higher discharge energy increased crater formation, recast layer thickness, and reinforcement particle dislodgement, while prolonged T_ON at low I_P promoted distributed thermal damage and directional recast patterns.