EDM machining characteristics of bamboo leaf ash and alumina reinforced aluminum hybrid metal matrix composite using Multi-response optimization by grey relational analysis

Abstract

In this research work, aluminum hybrid composites using bamboo leaf ash (BLA) and alumina have been fabricated via stir casting. Three hybrid composites viz: A713 + 2%BLA + 2%Al2O3, A713 + 2%BLA + 4%Al2O3, A713 + 4%BLA + 2%Al2O3 are fabricated successfully and EDM machining of these three composites is performed. The EDM machining experiments of the three hybrid composites, have been designed using Taguchi L27 orthogonal array design of experiments (DOE) considering current (A), duty cycle (%), gap voltage (V) and different percentage composition of the reinforcements. The effect of the EDM machining process parameters on the output responses such as surface roughness (Ra) and material removal rate (MRR) are evaluated using grey relational analysis.

Enhancing machining efficiency in hybrid metal matrix composites through EDM parameter optimization via grey relational analysis

“…Additionally, the surface exhibited an increased density of cracks, providing insights into the evolving material responses. The similar observations were observed by Devi et al and Prakash et al [23,24] that controlling discharge energy and current levels during the machining process is crucial for achieving the desired surface quality. Additionally, managing the debris generated during the process is important to prevent the formation of oxides and carbides, which can negatively impact the final surface quality.…”

Thermal modelling and Parametric optimization for Machining of Aluminum (Al-10%SiCmicro-SiCnano) based hybrid composite using Spark Erosion

“…Same has been reported in literature where Ramulu M. and Spaulding M. showed that finest hole quality obtained by EDM are at lower current settings [47]. Devi et al [13] also found that lowest peak current gave optimum results. The increase in dilation in hole diameter and hole taper at 6 A current results seems to be contrary to usual approach and may be due to creeping of human error as in order to check the completeness of the hole drilled, it was removed in-between.…”

“…[12] A713-2% Bamboo Leaf Ash -2% Al2O3, A713-4% Bamboo Leaf Ash -2% Al2O3, A713-2% Bamboo Leaf Ash -4% Al2O3 [13] Al 2024 -6% TiB2-12% B4C [14] Al-10% wt SiC-5% wt B4C-1 % wt Mg [15] Results show that different materials have different effects on the EDM process parameters and performance parameters. For example, hybrid composites with SiC and B4C reinforcements require a long duration of spark and higher flushing pressure [5].…”

Impact of SiC Particle Incorporated Dielectric Medium on Machining Performance of AA7050/SiC/Al2O3 Hybrid Composites

“…18 With increase in current MRR increases until a saddle point of 15 A, thereafter it starts to decreases. 19 With increase in current it generated the heat of high intensity which erodes the material at higher rate until the current of 15 A. For the parametric value of 20 A, mean MRR reduces to 58.18 mg min −1 from 63.61 mg min −1 owing to the densification of plasma channel.…”