Selection of Optimum Parameters in Non Conventional Machining of Metal Matrix Composite

Abstract

Aluminium metal matrix composites (AMMCs) are now gaining their usage in aerospace and automotive industries. Because of their inherent nature, difficult to machine, they find very little applications in other sectors. Even non traditional processes like Laser Jet Machining and Electro Discharge Machining result in significant sub surface damage to the work. In this paper, an attempt is made to machine the A356/SiC p composite work material using Electro Chemical Machining process. Silicon carbide with an average particle size of 40 microns is tried in three different proportions, namely 5%, 10% and 15% by weight. Taguchi's L 27 orthogonal array is chosen to design the experiments and 54 trials are conducted to study the effect of various parameters like applied voltage, electrolyte concentration, feed rate and percentage reinforcement on maximizing the material removal rate. ANOVA results have shown that all the four selected factors are significant and from the S/N graph the optimum level of each factor is chosen. A mathematical model is also developed using the regression method. Confirmation experiment is conducted and found that the data obtained have close match with the data predicted using the model.

Investigations on Machining of Monel 400 Alloys Using Electrochemical Machining with Sodium Nitrate as Electrolyte

“…1 shows the experimental set up used for the experimentation. The process parameters selected for the present analysis are electrolyte concentration (EC), voltage (V) and inter electrode gap because of their significant effect on the ECM performances based on literature [5][6][7][8]. Their effects on the MRR and R a are tested through the set of planned experiments based on central composite design (CCD) of RSM.…”

A review on machinability and optimization of machining parameters of metal matrix composites

“…Senthil Kumar et al [94] have also noticed similar behaviour being exhibited by AMMC sample embedding with 10 wt.% SiCp reinforcement synthesized via stir casting route. Kumar et al [95] processed Al/SiCp composite through ECM based on L27 design of experiments for analyzing the influence of factors like strength of electrolyte, feed and potential difference between the electrodes, with varying percentage of reinforcement in increments of 5% by weight on MRR.…”

Modeling of metal removal rate in machining of aluminum matrix composite using artificial neural network

“…Experiments are planned according to the Taguchi’s L 27 orthogonal array 22 as his parameter design is widely used in conducting and analyzing experiments for optimization. 23,24 The method helps in reducing cost, material, and time in conducting experiments and makes the process robust i.e., least sensitive to uncontrolled factors involved in experimentation.…”