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Journal of Polymer & Composites Original Research Special issue

Improvement of Geometric Tolerances and Mechanical Properties of Aluminum Hybrid Metal Matrix Composites

  1. Lokanadham Dharmana Department of Mechanical Engineering, Aditya Institute of Technology and Management, Tekkali
  2. K DurgaPrasad Department of Mechanical Engineering, Aditya Institute of Technology and Management, Tekkali
  3. Duppala Azad Department of Mechanical Engineering, Aditya Institute of Technology and Management, Tekkali
  4. B Roop Sandeep Department of Mechanical Engineering, Aditya Institute of Technology and Management, Tekkali
  5. D Bhanuchandra Rao Department of Mechanical Engineering, Aditya Institute of Technology and Management, Tekkali
  6. S Hari Prasad Department of Physics, BS&H, Aditya Institute of Technology and Management (AITAM), Tekkali – 532201, Srikakulam

Abstract

In the field of metal matrix composite materials, there has been a generous thrust towards the development of electrical discharge machining (EDM). In this study, stir casted aluminum hybrid metal matrix composites were successfully machined using EDM by analyzing the input process parameters namely, pulse-on time, peak current, and gap voltage using L27 orthogonal array. The ideal conditions for various output responses such as material removal rate, circularity, and radial overcut were examined by employing grey relational analysis procedure by optimizing the various input process parameters. A response table was generated utilizing grey relational grading to determine the optimal individual parameter settings. From the ANOVA table, results highlighted the pivotal role of the current parameter, contributing 53.183% to overall performance. Optimal conditions identified included a peak current of 14.5 A, a pulse-on time of 50 µs, and a gap voltage of 45 V. Validation tests confirmed substantial improvements compared to initially predicted parameters. The machined surfaces were analyzed using mechanical testing methods, and observed maximum ultimate strength, hardness and wear resistance for the base material reinforced with 6 wt.% of titanium carbide (TiC), and 2 wt.% of boron nitrides (BN). The circularity and radial overcut of the machined surface distended with an increase in peak current throughout its range. The MRR deviation was increased with a combination of elevated peak current and lower pulse-on time.

Keywords

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