A Hybrid Design of Experiment Approach in Analyzing the Electrical Discharge Machining Influence on Stir Cast Al7075/B<sub>4</sub>C Metal Matrix Composites
Velusamy Mohankumar,
Sunderraj Kapilan,
Aruchamy Karthik,
Mylsamy Bhuvaneshwaran,
Carlo Santulli,
Durairaj Thresh Kumar,
Sivasubramanian Palanisamy,
Cristiano Fragassa
Affiliations
Velusamy Mohankumar
Department of Mechatronics Engineering, Akshaya College of Engineering and Technology, Coimbatore 642109, India
Sunderraj Kapilan
Department of Civil Engineering, Akshaya College of Engineering and Technology, Coimbatore 642109, India
Aruchamy Karthik
Department of Mechatronics Engineering, Akshaya College of Engineering and Technology, Coimbatore 642109, India
Mylsamy Bhuvaneshwaran
Department of Mechanical Engineering, K.S.R. College of Engineering, Tiruchengode 637215, India
Carlo Santulli
School of Science and Technology, University of Camerino, 62032 Camerino, Italy
Durairaj Thresh Kumar
Department of Mechanical Engineering, PTR College of Engineering and Technology, Madurai 625008, India
Sivasubramanian Palanisamy
Department of Mechanical Engineering, PTR College of Engineering and Technology, Madurai 625008, India
Cristiano Fragassa
Department of Industrial Engineering, University of Bologna, 40136 Bologna, Italy
The present work centers on aluminum-based metal matrix composites (AMCs), synthesized via stir casting and then processed by electrical discharge machining (EDM) in the case of Al7075 as a matrix and 6 wt.% boron carbide (B4C) as reinforcement. A design of experiment (DoE) approach, powered by hybrid optimization techniques (such as the entropy weight method (EWM), grey relational analysis (GRA) incorporated Taguchi method) was used to investigate the relationship between current (I), pulse ON time (Ton), pulse OFF time (Toff), and electrode gap (Gap) as input parameters and the material removal rate (MRR), tool wear rate (TWR), and surface roughness (SR) as response parameters. The results showed that an I = 140 A, Ton = 120 ms, Toff = 50 ms, and Gap = 0.4 mm combination gives the best response parameters of MRR = 0.5628 mm3/min, TWR = 0.0048 mm3/min, and SR = 4.4034 μs.
