Research Article Experimental Investigation and Optimization of Material Removal Rate and Tool Wear in the Machining of Aluminum-Boron Carbide (Al-B 4 C) Nanocomposite Using EDM Process A. Arunnath, 1,2 S. Madhu , 3 and Mebratu Tufa 4 1 Department of Mechanical Engineering, Saveetha School of Engineering, Saveetha Institute of Medical and Technical Sciences, Chennai 602105, India 2 Department of Mechanical Engineering, Faculty of Engineering and Technology, Vadapalani Campus, SRM Institute of Science and Technology, Chennai, India 3 Department of Automobile Engineering, Saveetha School of Engineering, Saveetha Institute of Medical and Technical Sciences, Chennai 602105, India 4 Department of Mechanical Engineering, Faculty of Manufacturing, Institute of Technology, Hawassa University, Hawassa, Ethiopia Correspondence should be addressed to S. Madhu; mathumarine@gmail.com and Mebratu Tufa; mebratu.tufa@hu.edu.et Received 14 June 2022; Accepted 19 July 2022; Published 21 August 2022 Academic Editor: Vijayananth Kavimani Copyright © 2022 A. Arunnath et al. is is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. Electrical discharge machining (EDM) is a cost-effective unconventional machining method used for machining any composites materials. EDM is based on the thermoelectric energy between the electrode and workpiece. In this work, boron carbide particles of 50 nm (6 wt.%) are reinforced with aluminum 7075 (94 wt.%) prepared using stir casting method. e stir casting process is carried out at speed of 700–800 rev/min. e fabricated aluminum-boron carbide nanometal matrix composites are used as workpiece (anode); copper electrode is used as tool (cathode). is work investigates the influence of EDM process parameters such as current (I), pulse on-time (t on ), and tool diameter (d) during machining of Al-B 4 C composite on metal removal rate (MRR) and tool wear rate (TWR). e design of experimental plan is executed by Taguchi approach, and the responses of each parameter are influenced by analysis of variances (ANOVA). Response table for average value of MRR and TWR shows that the current is the significant parameter affecting MRR and TWR. From this work, it was observed that material removal rate increased with increasing the current, and the tool wear rate decreases. 1. Introduction e input parameters were optimized by Box Behnken method, and quadratic model was suggested for output responses. e prepared specimen is machined using elec- trical discharge machining (EDM). e presence of graphite nanopowders in dielectric fluid notably improved the sur- face finish and enhanced MRR (material removal rate) and EWR (electrode wear rate) [1, 2]. e input process pa- rameters were optimized using L18 orthogonal array of Taguchi Method on AISI D2 steel specimen machined by electrical discharge machining (EDM). e electrical spark vaporized on work material there after it has been flushed out through fluid medium. It has been observed that in- creasing current leads to increasing the surface roughness, and CuW electrode prepared through powder metallurgy is better than conventional Cu electrode [3, 4]. e silicon powder mixed in dielectric fluid gives more MRR and better surface roughness. EDM is a very important machining method that is extensively and effectively used for the machining of such materials, exactly and cost-effectively within the high advance in business [5]. e experimental Hindawi Advances in Materials Science and Engineering Volume 2022, Article ID 4254024, 11 pages https://doi.org/10.1155/2022/4254024