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

doi:10.3390/met14020205

Metals (Feb 2024)

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

DOI: https://doi.org/10.3390/met14020205
Journal volume & issue: Vol. 14, no. 2
p. 205

Abstract

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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.

Published in Metals

ISSN: 2075-4701 (Online)
Publisher: MDPI AG
Country of publisher: Switzerland
LCC subjects: Technology: Mining engineering. Metallurgy
Website: http://www.mdpi.com/journal/metals

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