Study on the Wire Electrical Discharge Machining of AA 7075 Aluminum Alloy

In the present study, wire electrical discharge machining (wire EDM) behaviors of Aluminum alloy 7075-T6 were investigated and the influence of the wire tension, voltage and peak current on the surface quality were evaluated. Experiments were performed based on the Taguchi L
₂₇
full factorial experiment design and optimal cutting parameters for surface quality were determined. The mean effect plot and analysis of variance (ANOVA) were used to evaluate the cutting parameters on the machined surface. Experiment results showed that the most efficient parameter on surface roughness was the peak current value. It was observed that aluminum was affected by the electric arc during the wire EDM process and caused the crater formation on the machined surface of the aluminum alloy. The vertical crack connected with non-continuous horizontal crack parallel to the machined surface of the workpiece were seen on the machined surface.