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This work was undertaken to study the effect of some of the main electro-discharge machining process parameters such as flushing pressure, current, pulse-on-time, and vibration on the tool wear rate (TWR), and metal removal rate (MRR) of Al 6061 alloy with 10 wt.-% TiB 2 p (titanium boride particulate) composites. The response surface methodology was used to determine the most important criteria to maximize the MRR and minimize the TWR. The experimental procedure was designed based on second-order rotatable central composite design. Sensitivity analysis was used to identify the important criteria and classify them by their order of importance in model validation. Many efforts were made to compare the calculated output of the data obtained. Pulse-on-time sensitivity was found to exert a more significant effect on MRR and TWR than did other criteria. The surface plots were prepared for both MRR and TWR. MRR value increases with an increase in peak current. It occurs in a workpiece that transfers the heat directly to the workpiece, and these functions increase TWR. This occurs because of an increase in MRR and a decrease in TWR.

Modeling of machining parameters for MRR and TWR in EDM characteristics on Al/10 wt.-% TiB 2 composites