The current research investigates the effect of electric discharge machining (EDM) and material parameters on material removal rate (MRR), tool wear rate (TWR) and surface roughness (Ra) while machining the novel aluminium rock dust composite. Experiments have been performed in Vidyunt EM 150 EDM machine by considering parameters namely discharge current, pulse ON time, pulse OFF time, reinforcement size and level. The composites have been prepared through stir casting method by reinforcing various sizes (10, 20 & 30 µm) of rock dust particles with aluminium 6061 and at different levels (5, 10 & 15%). Since the number of input parameter is more, Taguchi’s design of experiments has been used to reduce the number of trials and grey relational analysis (GRA) technique has been used for optimization. Analysis of variance has been performed to identify the significance of the parameters and it has been found that all the considered parameters have significant effect on response variables. But in the case of multi performance characteristics analysis, only pulse ON time and pulse OFF time have the significance over GRG. Pulse ON time has the highest influence (55.36 %) on the GRG followed by pulse OFF time with 17.6% and rock dust weight % with 7.8%. From the confirmation experiments, it could be well said that the developed regression equations predicts the response parameters with minimal error and the grey relational grade has been improved significantly.

中文翻译：

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材料和加工特性对6061Al /岩粉复合材料放电加工的影响

当前的研究调查了在加工新型铝粉尘复合材料时，电火花加工（EDM）和材料参数对材料去除率（MRR），工具磨损率（TWR）和表面粗糙度（Ra）的影响。在Vidyunt EM 150 EDM机床上通过考虑以下参数进行了实验：放电电流，脉冲开启时间，脉冲关闭时间，增强材料尺寸和强度。通过搅拌铸造法，通过用铝6061增强各种尺寸（10、20和30 µm）的岩尘颗粒并以不同的含量（5、10和15％）来制备复合材料。由于输入参数的数量更多，因此Taguchi的实验设计已用于减少试验次数，而灰色关联分析（GRA）技术已用于优化。已经进行了方差分析以识别参数的重要性，并且已经发现所有考虑的参数对响应变量具有显着影响。但是，在进行多性能特征分析的情况下，只有脉冲接通时间和脉冲断开时间比GRG有意义。脉冲开启时间对GRG的影响最大（55.36％），其次是脉冲关闭时间为17.6％，岩粉重量％为7.8％。从确认实验来看，可以说开发的回归方程预测了误差最小的响应参数，并且灰色关联度得到了显着提高。但是，在进行多性能特征分析的情况下，只有脉冲接通时间和脉冲断开时间比GRG有意义。脉冲开启时间对GRG的影响最大（55.36％），其次是脉冲关闭时间为17.6％，粉尘重量百分比为7.8％。从确认实验来看，可以说开发的回归方程预测了误差最小的响应参数，并且灰色关联度得到了显着提高。但是，在进行多性能特征分析的情况下，只有脉冲接通时间和脉冲断开时间比GRG有意义。脉冲开启时间对GRG的影响最大（55.36％），其次是脉冲关闭时间为17.6％，岩粉重量％为7.8％。从确认实验来看，可以说开发的回归方程预测了误差最小的响应参数，并且灰色关联度得到了显着提高。