Wire Electric Discharge Machining of Aluminium Hybrid Composite: Renewable Energy Based IoT Approach

Abstract

Wire Electric Discharge Machining (WEDM) has been recognized as one of the optimum methods for machining of harder aluminum-based hybrid metal matrix composites (AHMMC). This method is used to optimize the major control aspects of a machine and they are current, pulse duration, and rate of feed of wire on kerf width (KRW) and Surface roughness (Ra) of hybrid composites made of aluminum Al6351 as the metal matrix (AMMHC). The AMMHC has been created via a stir casting technique by adding SiC and B4C with an Al6351 matrix. Box-Behnken design (BBD) has been used to conduct tests in order to parametrically optimize the WEDM process. The optimization of KRW and Ra is identified using 3-D surface plots, graphs and response table of ANOVA as well as by employing Response Surface Methodology (RSM). Internet of Things (IoT) is implemented to monitor the quality of electrolyte that is used in WEDM. It has been identified that the current has a major contribution in both KRW and Ra factors. A lower current is preferred for a lower KRW whereas higher current improves Ra value.