Optimization of SiC Abrasive Parameters on Machining of Ti-6Al-4V Alloy in AJM Using Taguchi-Grey Relational Method

The demand for hybrid composite materials has been expanding globally in all kinds of mechanical industries. Drilling is one of the basic operations required in manufacturing of various components and choosing optimum parameters of drilling is vital for getting good quality holes. The main objective of our work is to determine the ideal parameters of drilling and tool coatings required to minimize the thrust force and torque in drilling and to maximize the material removal rate (MRR) using Grey–Taguchi technique. Hybrid composite specimen made by reinforcing Al7075 alloy with 4% of aluminum oxide and 2% of boron nitride in stir casting process and drilling was carried out in a sequence at different drilling feed rates (40, 80, and 120 mm/min) and spindle speeds (1,200, 2,400, and 3,600 rpm) in a vertical machining center attached with drill tool dynamometer, using twist drills of diameter 5 mm and point angle 118° made of uncoated carbide, diamond-like carbon (DLC)-coated carbide and high carbon (HC)-coated carbide. The recorded thrust force and torque from the dynamometer and the computed MRRs during each drilling operation are tabulated as per Taguchi’s L27 orthogonal array and the results are analyzed using hybrid Grey–Taguchi technique. In our analysis, the optimum thrust force of 62.12 N and torque of 0.766 Nm were obtained when using a DLC-coated tool at a maximum speed of 3,600 rpm and minimum feed rate of 40 mm/min. An optimum MRR of 178.79 mm3/s was obtained while using DLC coated at a maximum speed of 3,600 rpm and a maximum feed rate of 120 mm/min.

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“…where ψ i represents the normalized SNR value and λ i represents SNR value for any particular response for an experiment [14].…”

Section: Methodsmentioning

confidence: 99%

Analysis of MRR, Thrust Force, and Torque in Drilling Al/BN/Al2O3 Composites using Hybrid Grey–Taguchi Technique

Babu

Dhanasekaran

Parthiban

et al. 2023

Journal of Nanomaterials

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“…Table 3 shows the 15 experimental runs by considering the 3 factors at 3 levels. The MRR (gram/s) is the quantum of material removed per unit of time and is calculated using Equation (1). The weight of the job before machining (W bm ) and after machining (W am ) was determined using a digital weighing machine with a precision of ±0.001 g. The time (t) required for cutting the square slot of the defined size is measured using a stopwatch with an approximate precision of ±1 s.…”

Section: Methodsmentioning

confidence: 99%

“…Owing to excellent advantageous properties such as a low elastic modulus, high corrosion resistance, excellent strength, weldability, and heat-treatable nature, the titanium Ti6Al4V alloys have become more popular in widespread application areas such as automobiles, jet engines, power-generating components, body frame of aircraft, and medicated implants [1,2]. Due to the high fatigue strength and fracture-resistant characteristics of these metals, they exhibit wide applications [3,4].…”

Section: Introductionmentioning

confidence: 99%

“…Due to the high fatigue strength and fracture-resistant characteristics of these metals, they exhibit wide applications [3,4]. The engaging explicit qualities of Ti6Al4V alloys broaden its use in various fields [1]. However, the poor thermal conductivity of titanium alloys challenges its machinability in conventional manufacturing techniques [5][6][7].…”

Section: Introductionmentioning

confidence: 99%

“…They found pressure to be the most significant parameter affecting machining time and surface roughness. Saravanan et al [1] employed the Taguchi-gray relational technique for optimizing AWJ machining parameters for Ti6Al4V alloy. They considered SiC volume, SiC size, and abrasive flow rate (A f ) as potential parameters affecting MRR and SR and found that particle size was the significant variable for producing higher MRR with low SR. Karkalos et al [14] studied AWJ machining on Ti6Al4V alloy using glass beads as abrasives to investigate the economic and environmental score of sustainability for the process.…”

Section: Introductionmentioning

confidence: 99%

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Multi-Response Optimization of Abrasive Waterjet Machining of Ti6Al4V Using Integrated Approach of Utilized Heat Transfer Search Algorithm and RSM

et al. 2021

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Machining of Titanium alloys (Ti6Al4V) becomes more vital due to its essential role in biomedical, aerospace, and many other industries owing to the enhanced engineering properties. In the current study, a Box–Behnken design of the response surface methodology (RSM) was used to investigate the performance of the abrasive water jet machining (AWJM) of Ti6Al4V. For process parameter optimization, a systematic strategy combining RSM and a heat-transfer search (HTS) algorithm was investigated. The nozzle traverse speed (Tv), abrasive mass flow rate (Af), and stand-off distance (Sd) were selected as AWJM variables, whereas the material removal rate (MRR), surface roughness (SR), and kerf taper angle (θ) were considered as output responses. Statistical models were developed for the response, and Analysis of variance (ANOVA) was executed for determining the robustness of responses. The single objective optimization result yielded a maximum MRR of 0.2304 g/min (at Tv of 250 mm/min, Af of 500 g/min, and Sd of 1.5 mm), a minimum SR of 2.99 µm, and a minimum θ of 1.72 (both responses at Tv of 150 mm/min, Af of 500 g/min, and Sd of 1.5 mm). A multi-objective HTS algorithm was implemented, and Pareto optimal points were produced. 3D and 2D plots were plotted using Pareto optimal points, which highlighted the non-dominant feasible solutions. The effectiveness of the suggested model was proved in predicting and optimizing the AWJM variables. The surface morphology of the machined surfaces was investigated using the scanning electron microscope. The confirmation test was performed using optimized cutting parameters to validate the results.

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Recent Advancements and Challenges of Abrasive Jet Machining: A Review

Kandpal,

Singh,

Johri

et al. 2023

Advances in Engineering Materials

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Optimization of SiC Abrasive Parameters on Machining of Ti-6Al-4V Alloy in AJM Using Taguchi-Grey Relational Method

Cited by 16 publications

References 25 publications

Analysis of MRR, Thrust Force, and Torque in Drilling Al/BN/Al2O3 Composites using Hybrid Grey–Taguchi Technique

Analysis of MRR, Thrust Force, and Torque in Drilling Al/BN/Al2O3 Composites using Hybrid Grey–Taguchi Technique

Multi-Response Optimization of Abrasive Waterjet Machining of Ti6Al4V Using Integrated Approach of Utilized Heat Transfer Search Algorithm and RSM

Recent Advancements and Challenges of Abrasive Jet Machining: A Review

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