Enhancing the geometric tolerance of aluminium hybrid metal matrix composite using EDM process

Abstract

A generous development of electrical discharge machining method has been stimulated in the province of metal matrix composites materials. In this extant work, the optimal condition for various output responses specifically circularity, cylindricity, perpendicularity and radial over cut are exposed by employing grey relational analysis procedure by optimizing the input process parameters alike pulse on time (T on), peak current (I) and gap voltage (V). The Hybrid Metal Matrix Composite material is evolved by handling the stir casting approach and then machined by exploring the input parameters using L 27 orthogonal array. From the consequences of grey relational grade, a response table was discovered to elect the optimal conditions of the individual parameter. The most contributing input parameter is current with 69.08%, which is determined from the ANOVA table. Finally, the optimal conditions which were acquired from the response table are peak current of 12 A, pulse on time of 50 µs and gap voltage of 30 V and also verified through an authentication test which illustrated that optimal process parameters are competently improved by 0.1452 when compared to the predicted parameter. The machined surface is analysed using a scanning electron microscope. The results palpated that the peak current increases the number of microvoids and size of the crater was increased and the poor surface finish was achieved.

Multi-objective optimization of drilling EDM process parameters of LM13 Al alloy–10ZrB2–5TiC hybrid composite using RSM

“…These excellent properties indeed made them to have extensive applications in the field of automobile for making components including engine blocks, disk brakes, pistons, connecting rod, cylinder liner, drive shaft, etc. [2]. In this work, LM13 aluminium alloy is selected as matrix material and the major constituent of 10-12% Si in the matrix offers high strength and wear properties over pure aluminium and it is highly used for making pistons in automobile sector [3].…”

Experimental investigation and statistical modeling of air-assisted EDM of Al–SiC composite with an improvised tool

“…Researchers have explored different avenues for optimization techniques in which gray relational analysis (GRA) optimization techniques have better responsiveness for different materials in the case of EDM [29,30]. In addition, several optimization techniques, such as Taguchi technique with GRA [31], artificial neural network (ANN), and evolutionary algorithms, such as particle optimization (PSO) and simulated annealing (SA) [32], have been pursued in the past few years. The genetic algorithm (GA) has been widely used for optimization in the literature.…”

Evaluation and multi-objective optimization of nose wear, surface roughness and cutting forces using grey relation analysis (GRA)

“…Very few researchers [4,15] have optimized the DSS machining with respect to output parameters. Researchers have used grey relation analysis (GRA) and analysis of variance (ANOVA) for optimization of machining process parameters and for analysing the effect of different parameters on response characteristics, respectively [21][22][23][24].…”

“…Costa et al [25] used weighted principal component analysis (WPCA) with Taguchi's S/N ratio for optimization of dry end-milling process. Senthilkumar et al [22] have optimized EDM process using GRA with ANOVA techniques. Similar attempt was made by Ren et al [23] so as to optimize high-speed milling process with six different carbide grade tools to optimize tool wear and surface roughness.…”

“…Very few researchers [24,[29][30][31] have attempted to optimize traditional machining process such as turning using Taguchi's GRA technique and ANOVA to find the significant effect of input parameter. Most of the researchers have used GRA with ANOVA for non-traditional machining processes [21,22]. It is quite important for a turning process to produce a good quality surface with minimum tool wear.…”