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Electrical Discharge Machining (EDM) is one of the most popular non-conventional machining processes that are being used in many high precision manufacturing industries. To increase the EDM performance, a hybrid technique, namely, powder mixed electrical discharge machining (EDM) (PMEDM) is generally used for getting more precise requirements. In this study, an experimental investigation is carried out in order to explore the machining performance of the PMEDM process on Ti-6Al-4V alloy using copper (Cu) powder in the EDM oil dielectric. Taguchi’s L18 orthogonal array design has been utilized for design of experiments and the analysis of variance (ANOVA) has been performed with the help of Minitab-19 software. The optimal parametric setting of Cu powder mixed EDM has been found utilizing the Taguchi - Grey Relational Analysis (GRA) integrated approach and also validation of optimal parametric setting is done through experimentation. It is a novel approach for machining Ti-6Al-4V alloy by this PMEDM technique in which the surface quality has been improved significantly with the addition of suitable amount of Cu powder into the dielectric medium.

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With the enhancement in science and technology, necessity of complex shapes in manufacturing industries becomes essential for more versatile applications. These lead to demand for light weight and durable materials for applications in aerospace, defence, automotive, as well as sports and thermal management. Due to its high-tech structural, functional applications like defence, automobile, aerospace, thermal sensitive materials. Al-Matrix composites are considered as one of those classes of advanced engineering materials. In the present study, Al-RHA (Rice Husk Ash) composites are prepared by powder metallurgy route using 10% and 15% RHA by weight as reinforcement. Presence of abrasive particles leads to difficulty of conventional machining on Al-RHA composites hence non-conventional machining WEDM (Wire-Electric Discharge Machining) has been investigated. Suitable machining parameters for composites using wire EDM have been tried to get maximum material removal rate and speed. Optimizations of experimental parameters have been studied using Taguchi and Anova to standardize the process parameters for machining. Prime process parameters like servo-voltage, pulse-on time and pulse-off-time have been taken into consideration to study cutting quality of Al-RHA Metal matrix Composite using cutting speed as response parameters while effect of RHA weight fraction addition is also considered for evaluation to understand its influence on affecting the response.

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