In this research, the significance of particle reinforcement and the effect of wire materials on machining of AA6061-TiB₂ composite by Wire Electrical Discharge Machining (WEDM) was investigated. Stir cast AA6061–TiB₂ (varying 5, 10, and 15 wt.%) was used as the work material for this present study owing to its superior mechanical properties and profound applications. WEDM is the most viable cutting process to produce intricate shapes and sharp corners with good surface texture. Taguchi methodology was used to conduct the experiments. Phase constituents of the work material were observed using XRD analysis. The results revealed that aluminium and titanium diboride are the major phase constituents without any reaction phases. Metallographic analysis was conducted to figure out the erosion mechanism and crater formation during spark discharge. The experimentation reveals that the percentage of particle reinforcement was the dominating factor in surface quality (62.04%) and machinability (34.2%). The TiB₂ (5 wt.%) reinforced composite exhibits excellent machinability and surface quality. Furthermore, in terms of machining rate, zinc-coated brass wire performs better than plain brass wire. Contrastingly, plain brass wire exhibits superior surface quality. In addition to that multi-objective optimization was performed using desirability analysis to achieve higher material removal rate and lower surface roughness. After the confirmation test, it is seen that the experimental values are in close agreement with the estimated values.

在这项研究中，研究了颗粒增强的重要性和线材对线切割 (WEDM)加工 AA6061-TiB ₂复合材料的影响。搅拌浇铸 AA6061–TiB ₂（不同的 5、10 和 15 重量％）由于其优异的机械性能和广泛的应用而被用作本研究的工作材料。WEDM 是最可行的切割工艺，可生产具有良好表面纹理的复杂形状和尖角。使用田口方法进行实验。使用XRD分析观察工作材料的相成分。结果表明，铝和二硼化钛是没有任何反应相的主要相成分。进行金相分析以找出火花放电过程中的侵蚀机制和火山口的形成。实验表明，颗粒增强的百分比是表面质量 (62.04%) 和可加工性 (34.2%) 的主要因素。TiB ₂(5 wt.%) 增强复合材料表现出优异的机械加工性和表面质量。此外，在加工速度方面，镀锌黄铜线的性能优于普通黄铜线。相比之下，普通黄铜线表现出优异的表面质量。除此之外，还使用合意性分析进行了多目标优化，以实现更高的材料去除率和更低的表面粗糙度。经过确认测试，可以看出实验值与估计值非常吻合。