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The present study deals with the machining of hybrid Al 7075/B4C/Gr composite using Abrasive Aqua Jet Machining. The effects of selected input factors, i.e., water jet pressure (WJP), stand-off distance (SOD), and traverse speed (TS) on the performance characteristics, namely taper angle (TA), surface roughness (Ra), and the material removal rate (MRR) are investigated. The experimental runs and test strategies are formulated using the Response Surface Methodology-Central Composite Design approach. Analysis of Variance (ANOVA) was used to examine the effect of input factors and their interactions with performance characteristics. MRR, Ra, and TA optimum condition and mathematical equations were also developed. Further, the multi-optimization method “Technique for Order of Preference by Similarity to Ideal Solution” is considered to find out the best combinations of input factors for optimized output factors on the hybrid composite. The ANOVA results confirm that among the input factors, WJP and SOD are the most significant factors, and the percentage distribution of input factors are found to be jet pressure (55.21%), stand-off distance (23.36%), and traverse speed (2.56%). The multi-objective optimum conditions of the input factors are WJP (A1) 210 bar, SOD (B1), and TS (C3) 30 mm/min, that produce optimal values of the considered responses, i.e., MRR up to 4.8703 mm3/min, Ra up to 3.57 μm and TA up to 0.189°. The TA has improved by 49.6% through the multi-objective optimum results when compared with single parameter optimized results. Article Highlights Hybrid Al7075/B4C/Gr composite fabricated through the rotary stir casting technique Experimental planning and designing layouts using Response Surface Methodology scheme and mathematical equations are produced with Design Expert 11.0. The best TA was obtained by RSM-TOPSIS approach, found at a lower WJP and SOD and a higher TS.

In this study, the effects of the process parameters on their performance characteristics of lead-induced Ti-6Al-4V alloy were investigated. Taguchi’s [Formula: see text] orthogonal array (OA) has been used to conduct the experiments. Four process parameters were considered each at three levels. Peak current, pulse-on-time, servo voltage and pulse-off-time were selected as process parameters on performance characteristics, namely, material removal rate (MRR), surface roughness (SR) and dimensional deviation (DD). A multi-attribute decision-making (MADM) technique, namely, analytic hierarchy process (AHP) and technique for order of preference by similarity to ideal solution (TOPSIS), has been used to investigate the multiple response characteristics. The weights for performance characteristics are determined by AHP. Finally, analysis of variance method has been employed effectively to bring out the influence of the process parameters associated with each performance characteristic, namely, maximization of MRR and minimization of SR and DD.

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