Optimization of machining parameters in turning of hybrid aluminium-matrix (LM24–SiCp–coconut shell ash) composite

Abstract

In any machining process, the vital part is determination of the optimum values for the process parameters to attain the highest desired quality at a low machining cost. This paper mainly focuses on the surface-roughness optimization in the turning of a hybrid aluminium-matrix (LM24-SiCp-coconut shell ash) composite through the Taguchi method and a genetic algorithm. All composite samples for the study were prepared under the optimal squeeze-casting conditions and experimental trials were selected based on the L9 (3) 4 orthogonal array. The main response considered in this study related to the surface roughness, and machining parameters such as the cutting speed, feed rate, depth of cut and tool-nose radius were taken into consideration. The surface roughness was tested on the composites turned with a high-speed CNC lathe machine. From the experimental data, a regression model of the surface roughness was developed. The optimum machining conditions were obtained through the Taguchi method and a genetic algorithm and checked through confirmation experiments. In this study, it was concluded that the genetic algorithm used for determining the optimum machining conditions showed better results than the experimental outcome based on the orthogonal array and the optimum conditions obtained with the Taguchi method. Keywords: LM24 aluminium alloy, silicon carbide particles, coconut shell ash, surface roughness, Taguchi method, genetic algorithm V katerem koli postopku mehanske obdelave je klju~nega pomena dolo~itev optimalnih procesnih parametrov, ki omogo~ajo najvi{jo zahtevano kakovost obdelave pri najmanj{ih stro{kih. Avtorji so se v glavnem osredoto~ili na optimizacijo parametrov stru`enja, ki dolo~ajo povr{insko hrapavost hibridnega kompozita (LM24-SiCp-pepel kokosovih lupin) z Al matrico. Za to so uporabili Taguchijevo metodo in genetski algoritem. Vsi vzorci za pri~ujo~o {tudijo so bili izdelani s postopkom visoko tla~nega litja v testastem stanju (angl.: squeeze casting) pri optimalnih parametri~nih pogojih. Eksperimentalni preizkusi so temeljili na izbrani L9 (3) 4 ortogonalni matrici. Glavni vplivni parametri povr{inske hrapavosti, obravnavani v tej {tudiji, so bili: hitrost rezanja, hitrost podajanja, globina reza in polmer konice plo{~ice rezilnega orodja. Povr{insko hrapavost kompozitnih vzorcev so preverjali z merilnikom Mitutoyo SJ-210 po zelo hitrem stru`enju na ra~unalni{ko vodeni (CNC) stru`nici. Na osnovi eksperimentalnih podatkov so razvili regresijski model za povr{insko hrapavost. Optimalne pogoje mehanske obdelave so dosegli s pomo~jo Taguchijeve metode in genetskega algoritma in jih preverili s pomo~jo eksperimentalnih postopkov. Avtorji zakljuujejo, da optimalni pogoji mehanske obdelave, dolo~eni z genetskim algoritmom, dajejo bolj{e rezultate kot eksperimentalni rezultati, ki temeljijo na optimalnih pogojih, dolo~enih s Taguchijevo metodo za izbrano ortogonalno matrico. Klju~ne besede: Al zlitina LM24, silicij karbidni delci, pepel kokosovih lupin, povr{inska hrapavost, Taguchijeva metoda, genet...

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Mechanical and tribological behaviours of aluminium hybrid composites reinforced by CDA-B4C

“…The benefits of adding agro waste are low cost, ease of access, low density and reduced pollution. Agro waste like ground nut shell ash (GSA) , bamboo leaf ash(BLA), rice husk ash (RHA), bagasse ash, palm kernel shell ash, maize stalk ash, corn cob ash (CCA), bean shell waste ash etc are researched and promising results have been reported [32][33][34][35][36][37][38][39][40][41][42][43][44]. Fatile OB et al have reported by adding the corn cob with SiC has no significant rise of porosity but while increasing the percentage of corn cob reduces the mechanical properties gradually.…”

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