Parametric Optimization of Aluminum Alloy 6061 Using Wire-EDM for Automotive Applications: A Taguchi-Based Approach

Year : 2025 | Volume : 13 | Special Issue 05 | Page : 293 302
    By

    Manojkumar Subrao Kate,

  • Priyaranjan Samal,

  1. Research Scholar, Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Vaddeswaram, Andhra Pradesh, India
  2. Assistant Professor, Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Vaddeswaram, Andhra Pradesh, India

Abstract

Machining hard materials with complex geometries presents numerous challenges, often requiring the use of non-traditional methods such as wire Electric Discharge Machining (EDM). However, wire EDM machines operate at slow speeds, and increasing the speed can negatively impact surface finish, making it a difficult task. The ongoing research investigates the machinability study of Aluminum Alloy 6061 using wire EDM, emphasizing the optimization of process parameters to enhance machining performance and surface quality. Experimental tests are conducted to assess the effects of key parameters like pulse-on time, pulse-off time, voltage, and feed rate on surface roughness. Through careful experimentation and statistical analysis, optimal parameters are identified to minimize surface roughness. The Taguchi method is applied to link process parameters with machining performance, identifying the optimized parameter combinations for superior results. The study revealed that Pulse on Time significantly impacts surface roughness and material removal rate in wire EDM machining of the aluminum alloy. This research enhances understanding of the process, offering critical insights for optimizing parameters in industrial applications. This study improves comprehension of the wire EDM machining process for Aluminum Alloy 6061 and provides valuable insights for optimizing the process parameters in industrial settings. Improved surface quality through this methodology may lead to significant advancements in the precision manufacturing of Aluminum Alloy 6061 components.

Keywords: Wire, EDM, Taguchi method, AA6061, Non-traditional machining.

[This article belongs to Special Issue under section in Journal of Polymer and Composites (jopc)]

How to cite this article:
Manojkumar Subrao Kate, Priyaranjan Samal. Parametric Optimization of Aluminum Alloy 6061 Using Wire-EDM for Automotive Applications: A Taguchi-Based Approach. Journal of Polymer and Composites. 2025; 13(05):293-302.
How to cite this URL:
Manojkumar Subrao Kate, Priyaranjan Samal. Parametric Optimization of Aluminum Alloy 6061 Using Wire-EDM for Automotive Applications: A Taguchi-Based Approach. Journal of Polymer and Composites. 2025; 13(05):293-302. Available from: https://journals.stmjournals.com/jopc/article=2025/view=223405


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Special Issue Subscription Original Research
Volume 13
Special Issue 05
Received 13/11/2024
Accepted 21/06/2025
Published 18/07/2025
Publication Time 247 Days
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