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1 Composites Theory and Practice

1 2023

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WEDM parametric study of AA7075/6 wt.% Ni-COATED Al2O3(P) composite miniature GEARS

Praveen D.V., Raju M.V.J., Raju D.R.

Composites Theory and Practice

2023

R. 23, nr 2

89--96

Nowadays, gears are essential components in various electro-mechanical devices. Nevertheless, the fabrication of miniature-sized gears is very complicated. The present paper is focused on assessing the influence of the WEDM parameters on the material removal rate (MRR) and surface roughness (Ra) of AA7075/6 wt.% nickel-coated Al2O3 composite miniature gears. Initially, the theoretical design calculations were performed, and consequently the results were validated using ANSYS 19.0 software. Furthermore, experiments were modelled in accordance with Taguchi’s L9 orthogonal array. Optimal combinations of pulse on time, pulse off time and peak current were assessed using grey relational analysis (GRA) coupled with principal component analysis (PCA). The significance of the parametric influence on the machining responses was also evaluated using the ANOVA technique. Consequently, confirmation tests were conducted to verify the optimal parameters and the predicted results are in good agreement with the experimental findings.