The stir casting method was used for fabrication of 7075 aluminum alloy with 10 wt.% SiC particles of size 20-40 lm. The research objective of this paper are to achieve uniform distribution of SiC particles in the 7075 aluminum alloy matrix, characterization, and analysis of mechanical properties of composite formed. Experiments were carried out at stirring speeds of 500, 650, 750 rpm, and stirring period of 10 min. Microstructures of aluminum alloy and composites with 5, 10 wt.% SiC reinforcements were examined. The results reveal that composite produced at stirring speed of 650 rpm and stirring time of 10 min has uniform distribution of SiC particles. XRD and EDAX analysis were carried out for 7075 Al alloy and composite with 10 wt.% SiC reinforcement. No adverse reaction was observed in XRD and EDAX of composite with 10 wt.% SiC reinforcement. Tensile strength and hardness increased by 12.74% and 10.48%, respectively, with the increase in percentage of SiC reinforcement from 5 to 15 wt.%.
Optimization in turning means determination of the optimal set of the machining parameters to satisfy the objectives within the operational constraints. These objectives may be the minimum tool wear, the maximum metal removal rate (MRR), or any weighted combination of both. The main machining parameters which are considered as variables of the optimization are the cutting speed, feed rate, depth of cut, and nose radius. The optimum set of these four input parameters is determined for a particular job-tool combination of 7075AI alloy-15 wt. % SiC (20^0 fim) composite and tungsten carbide tool during a single-pass turning which minimizes the tool wear and maximizes the metal removal rate. The regression models, developed for the minimum tool wear and the maximum MRR were used for finding the multiresponse optimization solutions. To obtain a trade-off betM'een the tool wear and MRR the, a method for simultaneous optimization of the multiple responses based on an overall desirability function was used. The research deals with the optimization of multiple surface roughness parameters along with MRR in search of an optimal parametric combination (favorable process environment) capable of producing desired surface quality of the turned product in a relatively lesser time (enhancement in productivity). The multi-objective optimization resulted in a cutting speed of 210 m/min, a feed of 0.16 mm/rev, a depth of cut of 0.42 mm, and a nose radius of 0.40 mm. These machining conditions are expected to respond with the minimum tool wear and maximum the MRR, which correspond to a satisfactory overall desirability.
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