Development of Al -MoS2 MMC and modelling of machining parameters with

Wire cut Electric Discharge Machining (WEDM) is an vital technology, which is required for high – speed cutting and high – precision machining to enhance productivity and accuracy for manufacturing of press tools, moulds, prototype parts and complicated contours etc. The machining system involves many input parameters effecting output. The main objective of this work is to determine the optimum values of machining parameters for attaining economical and competent performance for machining Al6061 / MoS2 metal matrix composite (MMC). The MMC material was made by stir casting process and the specimen were prepared for machining as well as testing. The cutting operations were carried out on WEDM by varying the machining current on work pieces of thickness ranging from 5mm to 80mm. The surface roughness value was measured using Talysurf. The material removal rate (MRR) was computed by measuring cutting width using Profile projector. The optimal current value at which the machining is stable with high cutting speed is identified. Mathematical correlations are developed to determine the cutting parameters, the MRR and Surface roughness by using Origin software.