An investigation of material removal rate and surface roughness of squeeze casted A413 alloy on WEDM by multi response optimization using RSM

• The A413 alloy was successfully fabricated through squeeze casting route.
• It was observed from ANOVA for machining parameters such as Ton, Toff in WEDM.
• The average error percentage in RSM predicted.
• These results are confirmed by the confirmation run and it’s found to be in good agreement.

The machinability study on newly fabricated A413 alloy produced by squeeze casting route under optimal condition through wire electrical discharge machining process are also investigated as final one of the present work. The experiments were systematically carried out by adapting central composite rotatable design approach of response surface methodology to investigate the effect of wire electrical discharge machining parameters such as pulse on time, pulse off time and peak current on material removal rate and surface roughness. Analysis of variance was also carried out to check the significance of the models. The mathematical models were developed to predict the results which are within the limits of agreeable average error for material removal rate and surface roughness through additivity test. Desirability function approach was used to find the optimal parametric combinations for multi-objective optimization and successful machining of the castings. It has been verified by confirmatory experiment to show the efficiency of the proposed method. On the whole, it is stated that the investigation on squeeze casting and wire electrical discharge machining process parameter of A413 alloy have proved the better casting properties and machining quality. Hence, it is recommended for all industrial applications especially automobile, aerospace.

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