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Optimization of Micro-WEDM Process of Aluminum

Matrix Composite (A413-B4C): A Response Surface
Approach
a a a
Palani Sivaprakasam , P. Hariharan & S. Gowri
a
Department of Manufacturing Engineering , College of Engineering Guindy, Anna
University , Chennai , India
Published online: 13 Dec 2013.

To cite this article: Palani Sivaprakasam , P. Hariharan & S. Gowri (2013) Optimization of Micro-WEDM Process of Aluminum
Matrix Composite (A413-B4C): A Response Surface Approach, Materials and Manufacturing Processes, 28:12, 1340-1347, DOI:
10.1080/10426914.2013.823502

To link to this article: http://dx.doi.org/10.1080/10426914.2013.823502

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 Materials and Manufacturing Processes, 28: 1340–1347, 2013
Copyright # Taylor & Francis Group, LLC
ISSN: 1042-6914 print=1532-2475 online
DOI: 10.1080/10426914.2013.823502

Optimization of Micro-WEDM Process of Aluminum Matrix

Composite (A413-B4C): A Response Surface Approach
Palani Sivaprakasam, P. Hariharan, and S. Gowri

Department of Manufacturing Engineering, College of Engineering Guindy, Anna University, Chennai, India

This article presents a systematic approach for modeling and analysis of machining characteristics of Micro-Wire Electric Discharge
Machining (Micro-WEDM) process using the Response Surface Methodology (RSM). The effect of various input parameters, such as
voltage, capacitance, and feed rate on machining, performance of material removal rate (MRR), kerf width (KW), and surface roughness
(SR) was investigated. Experimental work was carried out on Aluminum Matrix Composite (A413-9% B4C) with zinc coated copper wire
using RSM with central composite design (CCD). The second order mathematical modeling and analysis of variance (ANOVA) were per-
formed to optimize the machining parameters. It has been found out that main and interaction effects are significant on the machining per-
formance. The optimized values of MMR, KW, and SR parameters were found to be 0.259943 mm3/min, 87 mm, and 0.97 mm, respectively.
Downloaded by [Aston University] at 19:28 25 August 2014

Keywords ANOVA; Micro-EDM; Micro-WEDM; Response surface methodology (RSM).

INTRODUCTION namely automotive industry, aerospace, defense, electro-

Metal matrix composite (MMC) materials are more
in demand in modern engineering applications due to
their lightness, high strength, thermal stability, and
wear resistance [1–3]. Aluminum-silicon (Al-Si) alloys
are mainly used as matrix materials in Aluminum Matrix
Composites (AMCs). AMCs are used in sporting goods,
electronic packaging, and automotive industries because
of excellent mechanical and physical properties [4]. They
are usually reinforced by carbon, Al2O3, SiC, boron
carbide, and also with fly ash. AMCs are very attractive
for their isotropic mechanical properties, and they are
costwise cheaper than all other metal matrix composites.
Machining of AMCs is very difficult by conventional
machining process, namely turning, milling, drilling, saw-
ing, etc., due to their extremely abrasive properties [5, 6].
Micro-Electro-Discharge Machining (Micro-EDM)
process is very similar to the macro-electrodischarge
machining process. Electro-discharge machining (EDM)
uses electrical discharges to erode electrically conductive
materials [7]. Micro-EDM is an effective technique in the
manufacturing of microcomponents due to the contactless
process irrespective of the material’s hardness [8]. High
precision micro-EDM has potential for machining with
submicron precision on various electrically conductive
materials [9]. Machining of MMCs has poor machin-
ability with conventional machining process. Tosun [10]
has introduced a mathematical model for predicting
the surface roughness (SR) values with varying input
parameters. Micro-WEDM is recognized as an effective
machining technique used in a wide range of applications,
Received January 4, 2013; Accepted June 21, 2013
Address correspondence to Palani Sivaprakasam, Department of
Manufacturing Engineering, College of Engineering Guindy, Anna
University, Chennai 600025, India; E-mail: shiva_au@rediffmail.com
nics, telecommunications, healthcare, environmental,
industrial products, and consumer products.
Most materials, such as MMC, ceramics, Inconel, and
tool steel, are used in micromolding, biomedical,
aerospace, and automotive applications. AMCs are used
in microparts such as microprocessor lids and integrated
heat sinks in electronic packaging. Micro-WEDM
extends its capabilities to microparts machining using
micro-wire tool and micro-energy pulse generator (1–10
mJ per pulse), with the advantages of noncontact machin-
ing, high efficiency, and low cost. From the review of
literature, it is observed that no studies were conducted
on machining of new and advanced materials such as
AMC in micro-WEDM process. Hence, there is need
for experimentation and mathematical model develop-
ment to enhance the machining characteristics of the
micro-WEDM process.
This article describes the determination of micro-
WEDM machinability of boron carbide (B4C)-reinforced
aluminum metal matrix composite. The effects of input
parameter on machining performance of micro-WEDM
are presented in this article. Material removal rate
(MRR) and SR are more significant parameters in manu-
facturing. Various investigations have been carried out
by several researchers for improving the MRR and SR
of the EDM and WEDM process [11–17]. However, lim-
ited research has been carried out on the micro-WEDM
process of aluminum matrix composites, especially
machining performances such as MRR, SR, and kerf
width (KW), modeling, and material properties. Since
machining with micro-WEDM is more expensive than
the conventional machining process, an appropriate
machining process parameter has to be selected for
economical machining operation. In these objectives,
the selection of optimal machining parameters and

1340
 OPTIMIZATION OF MICRO-WEDM PROCESS 1341

mathematical model for machining performance of

micro-WEDM are presented.

MATERIALS AND METHODS

Materials
Machining of AMCs is very difficult by conventional
machining process [18], and it was found out from the
literature that few artilces have been published on micro-
machining with AMC. The chemical composition of
Aluminum alloy is presented in Table 1. The X-ray
diffraction (XRD) pattern of Aluminum Alloy (A413)
is shown in Fig. 1. Zinc-coated copper wire was used as
an electrode tool material because it offers a higher
MRR, low tool wear, and fine surface finish, thus FIGURE 1.—XRD pattern of Aluminum Alloy (A413).
offering a good overall performance. The rectangular
work piece materials (10 mm
100 mm
1 mm) were
used for experimentation. Experimentation
The experimental work was carried out with DT-110
Response Surface Methodology (RSM) a three-axis automatic multiprocess integrated machin-
Downloaded by [Aston University] at 19:28 25 August 2014

ing system to study the effect of MRR, KW, and SR

Response surface methodology (RSM) is a collection
of statistical and mathematical techniques useful for
design of experiments and optimizing process parameters
[19]. RSM was used to predict the machining perfor-
mance of the micro-WEDM process in terms of MRR,
KW, and SR with input process parameters. The optimal
values were obtained from the RSM based on careful
planning and execution. Lin [20] evaluated the machining
characteristics of micro-EDM using RSM. The central
composite design is one of the efficient techniques
that could be applied to modeling of micro-WEDM in
RSM. The polynomial equation formed from RSM
was used to express the machining performance of the
micro-WEDM process as shown in Eq. (1). In this
experimentation, machining performance of MRR,
KW, and SR was modeled in terms of voltage, capaci-
tance, and feed rate:
Xn
y ¼ a0 þ ai xi
Xn i¼1 Xn
2
þ i¼1
aii x i þ a xx þ e
i<j ij i j
ð1Þ
where y is the response surface, xi and xj are the input
variables, the ai, aii, and aij are the tuning parameters
of linear, quadratic, and interaction effects, respectively.
The coefficients of the response surface have been
estimated by using the proposed scheme of the box and
hunter in the central composite design. This model
fits the second order response surface very accurately.
Replication was eliminated for finding the error term,
and the mean square error was estimated by replicating
the center points.
using the micro-WEDM setup shown in Fig. 2. A var-
iety of materials, metallic and nonmetallic, can be
machined to a high precision. DT-110 has the capability
of multiple machining processes such as micro-EDM,
microturning, micromilling, micro-electro chemical
machining (micro-ECM), and micro-wire electro dis-
charge grinding (micro-WEDG) with high machining
accuracy. The machine has its size of 1.5 m (W) X
1.1 m (D) X 1.9 m (H), including the controller unit
and dielectric supply unit. The maximum travel range
of the machine (DT-110) is 210 mm (X)
110 mm
(Y)
110 mm (Z). All the three axes have optical linear
scale with resolution of 0.1 micrometer with closed
feedback control for ensures high accuracy.
A cylindrical zinc-coated copper wire was used as the
tool electrode materials with a diameter of 70 mm and
workpiece materials were used as AMCs cut into thin
sheets 1 mm thick, 100 mm long, and 10 mm wide.
Commercial grade EDM oil was used as dielectric
fluid. The different input factors and their level of the
micro-WEDM process are depicted in Table 2.
A three-factor, three-level central composite design
was used to determine the optimal factors of MRR,
KW, and SR of the micro-WEDM process of AMCs.
The design variables were voltage (A), capacitance (B),
and feed rate (C), and their levels were coded 1, 0,
and þ1. The MRR, KW, and SR were selected as
response variables. The factorial fraction of central
composite design (CCD) is a full factorial design with
all the combinations of the factors at two levels (high
þ1 and low 1) and composed of the eight star points,
six central points (coded level 0), and six axial points

TABLE 1.—Chemical composition of Aluminum Alloy (A413).

Component Cu Si Mg Mn Fe Ni Ti Zn Pb Sn

Weight percent 0.013 11.48 0.02 0.01 0.52 0.019 0.005 0.012 0.002 0.001
 1342 P. SIVAPRAKASAM ET AL.

FIGURE 3.—Photographs of machined profile and kerf width (KW) (color

figure available online).

(2). SR values were measured with average of three repli-

FIGURE 2.—Setup for micro-WEDM experiments (color figure available
online).
Downloaded by [Aston University] at 19:28 25 August 2014
cations by a noncontact 3D Profiler (Talysurf CCI MP).
KW values were measured by video measuring system.
Figure 3 shows the image of machining profile and KW
of machined components. The experimental results of
machining performance of the micro-WEDM process
are presented in Table 3:

TABLE 2.—Design variable and their levels of the micro-WEDM process. Volume of material removal
MRR ¼ ð2Þ
Levels Time taken
Variable Symbol 1 0 1

Voltage (V) A 80 90 100

Capacitance (mF) B 0.01 0.1 0.4
RESULTS AND DISCUSSION
Feed rate (mm=sec) C 5 10 15 Based on statistical analysis, the model fits the experi-
mental data, model adequate, no significant lack of fits,
and has satisfactory R2 values of MRR, KW, and SR
(þ1.68, 1.68). Twenty different experimental combina- (0.9663, 0.9866, and 0.9614), respectively. The effect of
tions were chosen at random according to CCD in RSM. micro-WEDM parameters such as voltage, capacitance,
The experimental study was carried out based on the and feed rate was investigated using a CCD on various
CCD given in Table 3. MRR was calculated using Eq. response parameters presented in Table 3, using a series
of experimental runs.
Based on analysis of variance (ANOVA) test, p-values
TABLE 3.—Experimental results for MRR, KW, and SR. for MRR, presented in Table 4 linear terms voltage (A),
capacitance (B), feed rate (C), interaction term voltage
A B C Material with capacitance (AB) are statistically significant. The
Feed removal Kerf Surface
Voltage Capacitance rate rate, MRR width, roughness, statistical analysis (ANOVA) indicates that quadratic
Run (V) (mF) (mm=Sec) (mm3=min) KW (mm) SR, Ra(mm) model of MRR is statistically significant but lack of fit
is not. Insignificant factors are eliminated by backward
1 0 0 0 0.025084 97 2.19 elimination process, and the reduced model is shown
2 0 0 0 0.025694 97 1.77
3 1.68 0 0 0.027545 96 2.07
in ANOVA Table 4. (R2, adjusted R2 values of the
4 0 1.68 0 0.025992 94 3.20
model are 96.63% and 95.73%, respectively.) According
5 1 1 1 0.020042 96 3.06 to p-values for KW reported in Table 5, linear terms
6 1 1 1 0.015232 87 1.10
7 0 1.68 0 0.024028 88 0.92 TABLE 4.—Analysis of variance for MRR.
8 0 0 0 0.026618 97 2.07
9 0 0 0 0.027551 97 2.17 Sum of Degree of Mean F p-Value
Source square freedom square Value prob. > F
10 0 0 0 0.026297 96 1.72
11 1 1 1 0.025925 87 0.97 Model 0.0605 4 0.0151 107.44 <0.0001 Significant
12 1 1 1 0.033847 94 3.38 A: Voltage 0.0042 1 0.0042 29.79 <0.0001
13 0 0 1.68 0.035446 96 1.97 B: Capacitance 0.0022 1 0.0022 15.93 0.0012
14 1 1 1 0.035714 95 2.27 C: Feed rate 0.0504 1 0.0504 358.01 <0.0001
15 1 1 1 0.021056 97 1.15 AB 0.0036 1 0.0036 26.05 0.0001
16 1 1 1 0.036750 97 1.12 Residual 0.0021 15 0.0001
17 1.68 0 0 0.022000 90 1.16 Lack of fit 0.0018 10 0.0001 3.868 0.0742 Not
18 0 0 0 0.025463 96 2.15 significant
19 0 0 1.68 0.017504 97 1.97 Pure error 0.0002 5 4.84E-05
20 1 1 1 0.018968 98 2.55 Cor. total 0.0627 19
 OPTIMIZATION OF MICRO-WEDM PROCESS 1343
TABLE 5.—Analysis of variance for KW. namely voltage (A), capacitance (B), and feed rate (C).
Degree p-Value
The developed mathematical models are used to predict
Sum of of Mean F Prob. the MRR, KW, and SR using Design Expert Software
Source square freedom square Value >F with a coded unit as follows:
Model 239.3672 7 34.1953 119.53 <0.0001 Significant
A: Voltage 53.7392 1 53.7392 187.85 <0.0001
Model equation of MRR
B: Capacitance 46.0974 1 46.0974 161.14 <0.0001
C: Feed rate 3.2691 1 3.2691 11.42 0.0055 YMRR ¼ þ 0:26194 þ 0:017538  A þ 0:012824  B
AB 66.125 1 66.125 231.15 <0.0001
BC 3.125 1 3.125 10.92 0.0063 þ 0:060791  C  0:021428  A  B;
A2 20.3597 1 20.3597 71.17 <0.0001
B2 51.9818 1 51.9818 181.71 <0.0001 Model equation of KW
Residual 3.4327 12 0.2860
Lack of fit 2.0994 7 0.2999 1.124680776 0.4647 Not
significant YKW ¼ þ 96:69807 þ 1:98367  A þ 1:83723  B
Pure rrror 1.3333 5 0.2666
Cor. total 242.8 19  0:48926  C  2:87500  A  B  0:62500  B  C
 1:18272  A2  1:88983  B2 ;

voltage (A), capacitance (B), feed rate (C), interaction Model equation of SR
term AB, BC, A A, B B are statistically significant. It YSR ¼ þ 2:03491 þ 0:24533  A þ 0:78748  B
is also identified that quadratic model of KW is statisti-
Downloaded by [Aston University] at 19:28 25 August 2014

cally significant and lack of fit is not significant by þ 0:17750  A  B  0:12728  A2 :

statistical analysis. Insignificant factors are eliminated
by backward elimination process, and the reduced
model of KW is shown in ANOVA Table 5. (R2,
adjusted R2 values of the model are 98.66% and
97.45%, respectively.) According to p-values for SR
reported in Table 6, linear terms voltage (A), capaci-
tance (B), interaction term AB, and A A are statistically
significant. Thus, it is found that the quadratic model
of SR is statistically significant and lack of fit is not sig-
nificant by statistical analysis. Insignificant factors are
eliminated by backward elimination process, and the
reduced model of SR is shown in ANOVA Table 6.
(R2, adjusted R2 values of the model are 96.14% and
92.67%, respectively.)
Three independent variables, such as voltage (A),
capacitance (B), and feed rate (C) are considered; all
three are major factors in micro-WEDM affecting the
qualities of AMC; however, the voltage and capacitance
have a significant interaction. The second-order poly-
nomial equation is used to convey the MRR (YMRR),
KW (YKW), and SR (YSR) of the micro-WEDM process
with machining parameters for the micro-WEDM,
Analysis of MRR
The main and interaction effects of various process
parameters on MRR are presented in Table 4. It is found
that the discharge voltage (A), capacitance (B), feed rate
(C), interaction term voltage, and capacitance (AB) have
significant effect on the MRR. Figure 4 shows the three
dimensional (3D) response surface of MRR, varying dis-
charge voltage, and capacitance. As seen from Figs. 4
and 5, increase in the voltage value leads to an increase
in spark energy across electrode gap, and hence MRR
is found to be increasing. Similarly, the MRR tends to
increase with the increase in capacitance in its central
value, and then it gradually decreases within the work
interval due to high gap pollution and insufficient
flushing conditions. Increase in MRR usually has a
tendency to increase SR. The higher value of MRR
0.3675 mm3=min is achieved with voltage ¼ 100 V,

TABLE 6.—Analysis of variance for SR.

Sum of Degree of Mean F p-Value

Source square freedom square Value Prob. > F

Model 9.7807 4 2.4452 76.5941 <0.0001 Significant

A: Voltage 0.8220 1 0.8220 25.7477 0.0001
B: Capacitance 8.4689 1 8.4689 265.2868 <0.0001
C: Feed rate 0.2521 1 0.2521 7.8954 0.0132
AB 0.2377 1 0.2377 7.4465 0.0155
A2 9.7807 4 2.4452 76.5941 <0.0001
Residual 0.4789 15 0.0319
Lack of fit 0.2560 10 0.0256 0.5742 0.7871 Not
significant
Pure error 0.2229 5 0.0446
Cor. total 10.2595 19
FIGURE 4.—Surface response of MRR (color figure available online).
 1344
FIGURE 5.—Contour plot of MRR (color figure available online).
Downloaded by [Aston University] at 19:28 25 August 2014
capacitance ¼ 0.01 mF, and feed rate ¼ 15 mm=sec within
the experimental range. The contour plot of A and B
for predicting the MRR is depicted in Fig. 5, keeping C
as constant to a value of 10 mm=sec.
Analysis of KW
According to ANOVA shown in Table 5, the most sig-
nificant parameters with respect to KW are discharge
voltage (A), capacitance (B), feed rate (C), interaction
of voltage and capacitance (AB), capacitance and feed
rate (BC), pure quadratic effect of voltage (A2), and
capacitance (B2). From Figs. 6 and 7, it can be concluded
that minimum KW can be achieved using lower the dis-
charge energy and constant stable discharge circum-
stance. These will improve the dimensional accuracy
and reduction of radius while cutting a corner in micro-
machined components. It is also observed that increase
FIGURE 6.—Surface response of KW (color figure available online).
P. SIVAPRAKASAM ET AL.
FIGURE 7.—Contour plot of KW (color figure available online).
in the voltage leads to an increase in discharge energy
and hence KW increases. Similarly, the KW tends to
increase for increase in capacitance, and also at some
point KW decreases. Figure 7 shows the two dimensional
contour plot of voltage and capacitance; feed rate remains
fixed at 10 mm=sec. The lower value of KW 87 mm is
observed with the parameter combinations of voltage ¼
80 V, capacitance ¼ 0.01 mF, and feed rate ¼ 5 mm=sec.
Analysis of SR
Based on ANOVA shown in Table 6, it is found that
the discharge voltage (A), capacitance (B), interaction
term voltage and capacitance (AB), and pure quadratic
effect of voltage (A2) have significant effect on the SR.
Figure 8 shows the 3D response surface of SR, varying
discharge voltage and capacitance with fixed feed rate at
10 mm=s. It shows that when discharge voltage increases,
the SR parameter tends to increase noticeably. It is also
found that the SR parameter increases when the capaci-
FIGURE 8.—Surface response of SR (color figure available online).
 OPTIMIZATION OF MICRO-WEDM PROCESS 1345

Optimization of Response Parameters

The main aim of the present study is finding the opti-
mal machining conditions of the micro-WEDM process.
The response surface optimization based on desirability
analysis is an ideal technique for finding the optimal
machining condition of the micro-WEDM process [21].
Here, the goal is to maximize the material removal and
minimize the KW and SR. Desirability approach helps
to map between the predicted response ‘y’ and desirability
function ‘d.’ The desirability value varies from 0 to 1. If
the desirability value is zero, it indicates that the predicted
value is completely undesirable and for the desirability
value of one it is idle. The desiarability of corrsponding
response increases as the the value of d increases. The
one-sided transformation desirability function of maxi-
mization for MRR is shown in Eq. (3), and their of mini-
mization of KW and SR 9s shown in Eq. (4):

n
wt 0 ! y  ymax
yymin
FIGURE 9.—Contour plot of SR (color figure available online). d ¼ ymin  y  ymax ð3Þ
Downloaded by [Aston University] at 19:28 25 August 2014

ymax  ymin
1 ! ymax
TABLE 7.—Optimum machining conditions.
n
wt 1 ! y  ymin
Optimum yymax
combination
d ¼ ymin ymax ymin  y  y max; ð4Þ
0 ! ymax
A B C Predicted Actual
Response Goal Desirability (V) (mF) (mm=sec) value value
where ‘d’ is a desirability function of y, ymin and ymax are
MRR Maximum 0.842 80 0.01 15 0.0270943 0.259947 lower and upper limits of response value of ‘y,’ respect-
KW Minimum 0.842 80 0.01 15 87.0654 87 ively, and wt is weight, which can be varied from 0.1 to
SR Minimum 0.842 80 0.01 15 1.05233 0.97 10 to adjust the shape of desirability function. An overall
desirability function D (0  D  1) is defined as the
geometric mean of individual desirability functions. The
tance is increased. A higher voltage and capacitance multiobjective function is a geometric mean of all trans-
result in an increase in the amount of heat energy at formed responses of single objective problem shown in
the point of discharge; these will lead to the formation Eq. (5). The higher the D value is, the better desirability
of overheated pool of molten metal. A fraction of the of the combined response levels:
molten material is flushed away by dielectric while over-
heated molten metal evaporates, which results in the for- D ¼ ðd1 X d2 X . . . . . . dn Þ1=n : ð5Þ
mation of larger crater, thus producing a rough surface.
Figure 9 shows the 2D contour plot of voltage and Multiresponse optimization was carried out using
capacitance; feed rate remains fixed at 10 mm=sec, and desirability function in conjunction with RSM. Here
there are many combinations of voltage and capacitance the goal is to maximize the material removal and mini-
on the contour line of SR. mize the KW and SR. The weight values are assigned

FIGURE 10.—3D surface and roughness parameters (color figure available online).
 1346
for MRR, KW, and SR as one and equal importance
given to each response. The multiobjectives optimized
results for response parameters are shown in Table 7.
The optimum machining parameters are found to be
voltage of 80 V, capacitance of 0.01 mF, and feed rate
of 15 mm=sec. The optimized values of MRR, KW,
and SR parameters are 0.259943 mm3=min, 87 mm, and
0.97 mm, respectively. Figure 10 shows the 3D surface
image and surface parameters using Noncontact 3D
Profiler under the optimized machining conditions.
The final step is validating the model through the use
of optimal machining parameters using confirmation
test. Confirmation experiments were conducted at
optimum machining conditions. The optimized values
of MRR, KW, and SR parameters are found to be
0.2573 mm3=min, 87 mm, and 0.960 mm, respectively,
using the average of three confirmation experiments.
The confirmation experiment results were found within
95% confidence interval.
Downloaded by [Aston University] at 19:28 25 August 2014
CONCLUSION
This article presented optimization process para-
meters of micro-WEDM of AMC material by RSM.
The statistical analysis (ANOVA) highlighted the
major influencing machining parameters considered in
this study for improving machining performance of the
micro-WEDM process.
The second order mathematical modeling was
presented for predicting optimal conditions of MRR,
KW, and SR. Predicted and measured values were
reasonably close so that the models could be effectively
used for predicting the machining performance of the
micro-WEDM process.
The present study shows that all the three machining
parameters and voltage and capacitance (AB) and
capacitance and feed rate (BC) of their interactions have
significant effect on MRR of the micro-WEDM. The
voltage and capacitance (AB) capacitance and feed rate
(BC) of their interactions, and pure quadratic effect of
capacitance (B2) have significant effect on KW. The
two machining parameters voltage (A), capacitance
(B), voltage and capacitance (AB), capacitance and feed
rate (BC) of their interactions, and pure quadratic effect
of voltage (A2) have significant effect on SR.
Based on the optimization results, the combination of
voltage of 80 V, capacitance of 0.01 mF, and feed rate of
15 mm=sec could result in higher MRR equal to 0.2599
mm3=min, lower KW of 87 mm, and minimum SR of
0.97 mm.
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