Study on the effect of machining parameters on wire EDM of AA2219-T8

Aluminium alloy AA2219-T87, widely used in supersonic aircraft skins and structures as well as the Space Shuttle Standard Weight Tank, was studied to evaluate its machining behavior under wire electrical discharge machining (WEDM). WEDM removes material using electrical sparks between a tool wire and the workpiece, both submerged in dielectric fluid. This study investigates the effects of machining parameters—wire tension (WT), voltage, peak current, wire feed (WF), and water pressure (WP)—on surface quality. Experiments were conducted using a full factorial design following Taguchi’s methodology to determine optimal cutting parameters. Analysis of variance (ANOVA) and mean response plots were applied to assess surface finish and material removal rate (MRR). Results indicate that peak current significantly influences surface roughness, while other parameters also contribute to variations in MRR and surface quality. Observations revealed that the electric arc in WEDM impacts the aluminium surface, producing craters during machining.