High speed machining and optimisation of Al/SiC/Gr hybrid metal matrix composites using ANOVA and grey relational analysis

ABSTRACT

The objective of this work is to investigate the effect of graphite addition to Al/SiC composites manufactured by stir casting process. The reinforcement content of graphite was varied from 2.5 wt. % to 7.5 wt. %, for preparing three types of hybrid composites. Al/SiC/Gr hybrid composites prepared by stir casting method have uniform dispersion of SiC and Gr particle reinforcement. High-speed machining of Al/SiC/Gr was done in CNC machine using PCD insert at a cutting speed of 300, 400 and 500 m/min. From ANOVA analysis, cutting speed (48.76%) is the critical factor affecting surface roughness. Grey Relational analysis was done for simultaneous improvement of Material Removal Rate and surface roughness. Roughness values were predicted using Taguchi method and predicted values were compared with experimental results. Elemental chips produced during machining leads to reduced roughness values.

KEYWORDS:

• Hybrid metal matrix composites
• Al6061
• SiC
• graphite
• ANOVA
• high-speed machining

Acknowledgments

The authors thank Mr O.K. Ramanathan, RBC Engineering, Chennai for providing CNC machining facility and Dr V. Umasankar, Professor, VIT Chennai for the support.

Disclosure statement

No potential conflict of interest was reported by the authors.

Additional information

Notes on contributors

Elango M.

Elango M. is Assistant professor (Selection Grade) in the School of Mechanical Engineering VIT university Chennai campus. He has teaching experience of 18 years. He is working in VIT Chennai campus for 8 years. His main research interests are in the areas of Composite materials, machining and optimisation.

Annamalai K.

Annamalai K. is a professor in the School of Mechanical Engineering VIT university Chennai campus. He has rich teaching experience around 23 years in VIT. His main research interests are in the areas of Fatigue and Fracture mechanics and failure analysis of engineering components. He has published over 75 research papers in international journals and conferences. He is closely associated with few companies and government institutions as adviser in design and development of engineering components and resource person for training programs.