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The main aim of this study is to fabricate SiC particulate reinforced aluminum functionally graded (Al FGM) brake disc and to find the optimal friction and wear parameters using grey relational analysis. The A356-20%SiC p melt was processed using liquid metal stir casting technique followed by centrifugal casting resulting in the formation of a functionally graded Al FGM brake disc. Due to the centrifugal force, the hard SiC particles were moved towards the outer peripheral area of the brake disc, which enhances the wear resistance. The microstructural analysis is done on brake disc to show the segregation of SiC particle from outer periphery to inner region. The pins for conducting wear study are machined from particle-rich zone, particle intermediate zone and particle depletion zone at a distance of 15 mm, 45 mm, 75 mm respectively from the outer periphery of the brake disc. The analysis of variance is also done to investigate the major factors that significantly influence the wear behavior in Al FGM brake disc. The observed results show that the particlerich zone is the major effect on the dry sliding wear followed by applied load.

This study reveals the multi objective optimization of machining parameters in drilling of SiC reinforced with aluminium metal matrix composites through grey relational analysis. The composite is prepared with varying volume fraction of the reinforcement by liquid metal stir casting technique. Uniform distribution of SiC particle in the matrix is witnessed through microscopy study and observed that the hardness and strength on different composite. The drilling experiments were performed with coated carbide tool with different point angle such as 90o, 120o and 140o. Cutting speed, feed, point angle and volume fraction are considered as input parameters and the performance characteristics such as surface roughness and thrust force are observed as output response in this study. The significant contributions of these factors are determined using Analysis of Variance (ANOVA). The optimized process parameters have been validated by the confirmation test. The experimental result shows that point angle influences more on output performance followed by feed and cutting speed.

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