Optimization of WEDM process parameter on machining of aluminum reinforced with fly ash using grey relational analysis.

In non-conventional machining processes like WEDM, the most important aspect is the selection of optimal level of process parameters to obtain best output. The materials which can be easily machined by WEDM process are composites, carbides, super alloys, ceramics, steel with high resistant etc. Various applications in military, aerospace and automotive component manufacturing industries are now-a-days using Al metal matrix composites (AMMCs). The reinforcing particles used in the composite material are carbides (SiC, WC, B4C), oxides (ZrO2, Al2O3, ThO2). B4C is a replacement of Al2O3 and SiC because of high hardness nature, high strength, good chemical steadiness, low density (2.52 g/cm3) and significant wear resistance. But this reinforcement are costly which increases the manufacturing cost of the product. Fly ash as a industrial waste which is less expensive, light in weight and good compressive strength which can replace the traditional reinforcement which minimizes the cost of the product. The main aim of this work is to optimize the Wire EDM process parameters for example, input current, pulse 'on' time, pulse 'off' time, wire feed on the surface roughness and material removal rate of aluminum based composites (AMCs) by utilizing Gray taguchi investigation. [ABSTRACT FROM AUTHOR]