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In recent days, the silicon carbide particulate reinforced aluminium metal matrix composites are most promising material in various engineering applications due to their strength to weight ratio, wear resistance and thermal resistance over the non-reinforced alloys. However, these materials are very difficult to cut by conventional machining methods due to the presence of silicon carbide particles. To overcome this limitation, the wire electrical discharge machining (WEDM) is employed to machine these composites. The aim of this study is to optimize the process parameters in wire electrical discharge machining (WEDM) of Al6061/SiCp composite using AHP-TOPSIS method. Al 6061/2% SiCp/3 µm particulate metal matrix composite is fabricated by using stir casting method and the uniformity of particle distribution was analyzed by SEM. Taguchi L 18  orthogonal array is designed by considering various process parameters viz. Wire Type (WT), Pulse ON Time (T ON), Pulse OFF Time (T OFF), Wire Feed rate (WF) and Sensitivity (S) for conducting WEDM experiments. The obtained experimental results were analyzed and the results revealed that Sensitivity (S) is the prevailing factor on the response characteristics of WEDM followed by pulse ON time (T ON), wire feed rate (WF), Wire Type (WT) and pulse OFF time (T OFF).

Multi-response Optimization in Wire Electrical Discharge Machining (WEDM) of Al6061/SiCp Composite Using Hybrid Approach