Several components are made from Al-Mg-based composites. MoS2 is used to increase the composite’s machinability. Different weight percent (3, 4, and 5) of MoS2 are added as reinforcement to explore the machinability properties of Al-Mg-reinforced composites. The wire cut electrical discharge machining (WEDM) process is used to study the machinability characteristics of the fabricated Al-Mg-MoS2 composite. The machined surface’s roughness and overcut under different process conditions are discussed. The evaluation-based distance from average solution (EDAS) method is used to identify the optimal setting to get the desired surface roughness and overcut. The following WEDM process parameters are taken to determine the impact of peak current, pulse on time, and gap voltage on surface roughness, and overcut. The WEDM tests were carried out on three different reinforced samples to determine the impact of reinforcement on surface roughness and overcut. The surface roughness and overcut increase as the reinforcement level increases, but the optimal parameters for all three composites are the same. According to EDAS analysis, I3, Ton2, and V1 are the best conditions. Furthermore, peak current and pulse on-time significantly influence surface roughness and overcut.
This work presents the application of hybrid approach for optimizing the dry sliding wear behavior of red mud based aluminum metal matrix composites (MMCs). The essential input parameters are identified as applied load, sliding velocity, wt.% of reinforcement, and hardness of the counterpart material, whereas the output responses are specific wear rate and Coefficient of Friction (COF). The Grey Relational Analysis (GRA) is performed to optimize the multiple performance characteristics simultaneously. The Principle Component Analysis (PCA) and entropy methods are applied to evaluate the values of weights corresponding to each output response. The experimental result shows that the wt.% of reinforcements (Q=34.9%) followed by the sliding velocity (Q=34.5%) contributed more to affecting the dry sliding wear behavior. The optimized conditions are verified through the confirmation test, which exhibited an improvement in the grey relational grade of specific wear rate and COF by 0.3 and 0.034, respectively.
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