Optimum Machining Parameters for Al 7075 Hybrid Metal Matrix Composites Using Multi-objective Optimization Technique and the Modified Taguchi Approach

Full Text PDF

Open Access

Year : 2024 | Volume :11 | Special Issue : 08 | Page : 269-278

Harish Mugutkar

T. Vijaya Kumar

G. Murali

Nageswara Rao Boggarapu

1.1 Research Scholar, Department of Mechanical Engineering,Koneru Lakshmaiah Education Foundation, Green Fields,Vaddeswaram, Guntur, Andhra Pradesh, India

1.2 Assistant Professor, Department of Mechanical Engineering,Anurag University, Ghatkesar, Hyderabad, Telangana, India

2.1 Associate Professor, Department of Mechanical Engineering,Koneru Lakshmaiah Education Foundation, Green Fields,Vaddeswaram, Guntur, Andhra Pradesh, India

3.1 Professor, Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Green Fields,Vaddeswaram, Guntur, Andhra Pradesh, India

4.1 Professor, Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Green Fields,Vaddeswaram, Guntur, Andhra Pradesh, India

Abstract

Lightweight composite materials with improved mechanical properties are widely used in industries. There is a need to obtain optimum machining parameters of such hybrid composites. This paper uses reliable multi-objective optimization technique and modified Taguchi approach to determine optimal machining parameters such as speed (NS) varying from 1000 rpm to 1500 rpm, feed rate (FR) from 0.10 mm/rev to 0.20 mm/rev, depth-of-cut (DC) varied from 0.5 mm to 1.5 mm and percentage reinforcement (R%) varied from 2 to 6 to achieve maximum material removal rate (MRR) and minimum surface roughness (SR) of the hybrid composites. The hybrid metal matrix composite (i.e., Al 7075 reinforced with B4C and rice husk ash, RHA) is manufactured using a stir casting technique. A set of optimum machining parameters is found to be NS = 1500 rpm, FR = 0.1 mm/rev, DC = 1.5 mm and R% = 2. Empirical relationship for MRR and SR are developed in terms of the machining

Keywords: Depth-of-cut, Feed rate, Material removal rate, % reinforcement, Rice husk ash, Speed, Surface roughness, Turning operation

This article belongs to Special Issue Conference International Conference on Innovative Concepts in Mechanical Engineering (ICICME – 2023)

How to cite this article: Harish Mugutkar, T. Vijaya Kumar, G. Murali, Nageswara Rao Boggarapu. Optimum Machining Parameters for Al 7075 Hybrid Metal Matrix Composites Using Multi-objective Optimization Technique and the Modified Taguchi Approach. Journal of Polymer and Composites. 2024; 11(08):269-278.

How to cite this URL: Harish Mugutkar, T. Vijaya Kumar, G. Murali, Nageswara Rao Boggarapu. Optimum Machining Parameters for Al 7075 Hybrid Metal Matrix Composites Using Multi-objective Optimization Technique and the Modified Taguchi Approach. Journal of Polymer and Composites. 2024; 11(08):269-278. Available from: https://journals.stmjournals.com/jopc/article=2024/view=133078

Full Text PDF Download

Browse Figures

References

Padmakumar A.B., Vinayak R.M., Anand S.D. (2019). Particulate metal matrix composites and their fabrication via friction stir processing – a review, Materials and Manufacturing Processes, 34:8, 833-881, DOI: 10.1080/10426914.2019.1605181
Bahrami, A., Soltani, N., Soltani, S., Pech-Canul, M.I., Gonzalez, L.A., Gutierrez, C.A., Möller, A., Tapp, J., Gurlo, A. (2017). Mechanical, thermal and electrical properties of monolayer and bilayer graded Al/SiC/rice husk ash (RHA) composite, Journal of Alloys and Compounds, 699, 308-322, doi: 10.1016/j.jallcom.2016.12.339.
Mugutkar, H., Tamiloli, N., Kohir, V.V. (2019). The processing techniques and behaviour of aluminum metal matrix with different reinforcement materials, International Journal of Mechanical and Production Engineering Research and Development, 9:4, 793-804.
Shalok, B., Nilesh, D.G., Kaushik, M.P. (2020). A review on manufacturing the surface composites by friction stir processing, Materials and Manufacturing Processes, 36:2,135-170,DOI: 1080/10426914.2020.1813897
Gopal, P.M., Prakash, K.S., Jayaraj, S. (2018). WEDM of Mg/CRT/BN composites: effect of materials and machining parameters, Materials and Manufacturing Processes, 33:1, 77-84, DOI: 1080/10426914.2017.1279316
Prakash, K.S., Kanagaraj, A., Gopal, P.M. (2015). Dry sliding wear characterization of Al 6061/rock dust composite, Transactions of Nonferrous Metals Society of China, 25:12, 3893–3903. https://doi.org/10.1016/S1003-6326(15)64036-5
Kumar, H., Prasad, R., Kumar, P., Tiwari, S.P., Singh, J.K. (2020). Mechanical and tribological characterization of industrial wastes reinforced aluminum alloy composites fabricated via friction stir processing. Journal of Alloys and Compounds, 831:154832. http://dx.doi.org/10.1016/j.jallcom.2020.154832
Hossain, S.K.S., Roy, P.K. (2020). Waste rice husk ash derived sol: A potential binder in high alumina refractory castables as a replacement of hydraulic binder. Journal of Alloys and Compounds, 817:152806. http://dx.doi.org/10.1016/j.jallcom.2019.152806
Bahrami, A., Pech-Canul, M.I., Gutierrez, C.A., Soltani, N. (2015). Effect of rice-husk ash on properties of laminated and functionally graded Al/SiC composites by one-step pressureless infiltration. Journal of Alloys and Compounds 644:256-266. https://doi.org/10.1016/j.jallcom.2015.04.194
Deng, M., Zhang, G., Zeng, Y., Pei, X., Huang, R., Lin, J. (2016). Simple process for synthesis of layered sodium silicates using rice husk ash as silica source. Journal of Alloys and Compounds 683:412-417 https://doi.org/10.1016/j.jallcom.2016.05.115
Mugutkar, H., Tamiloli, N., Kohir, V.V. (2022). Comparative analysis of mechanical studies of Al7075 hybrid metal matrix composites as a functionality of Sio2% in RHA. Academic Journal of Manufacturing Engineering 20:2, 19-26.
Taskesen, A., Kutukde, K. (2014). Experimental investigation and multi objective analysis on drilling of boron carbide reinforced metal matrix composites using grey relational analysis. Measurement 47: 321–330, http://dx.doi.org/10.1016/j.measurement.2013.08.040.
Abhang, L.B., Hameedullah, M. (2012). Determination of optimum parameters for multi-performance characteristics in turning by using grey relational analysis. Int J Adv Manuf Technol 63:1, 13–24, http://dx.doi.org/10.1007/ s00170-011-3857-6.
Shi, K., Zhang, D., Ren, J. (2015). Optimization of process parameters for surface roughness and microhardness in dry milling of magnesium alloy using Taguchi with grey relational analysis, Int. J. Adv. Manuf. Technol. 81, 645–651. https://doi.org/10.1007/s00170-015-7218-8
Ghetiya, N.D., Patel, K.M., Kavar, A.J. (2016). Multi-objective optimization of FSW process parameters of aluminium alloy using Taguchi-based grey relational analysis. Trans Indian Inst Met 69, 917–923. https://doi.org/10.1007/s12666-015-0581-1
Nataraj, M., Balasubramanian, K. (2017). Parametric optimization of CNC turning process for hybrid metal matrix composite. Int J Adv Manuf Technol 93, 215–224. https://doi.org/10.1007/s00170-016-8780-4
Mia, M., Khan, M.A., Rahman, S.S., Dhar, N.R. (2017). Mono-objective and multi-objective optimization of performance parameters in high pressure coolant assisted turning of Ti-6Al-4V. Int J Adv Manuf Technol 90, 109–118. https://doi.org/10.1007/s00170-016-9372-z
Ross, P.J. (1989). Taguchi Techniques for Quality Engineering. McGraw- Hill, Singapore.
Singaravelu J, Jeyakumar D, Nageswara Rao B. (2012). Reliability and Safety Assessments of the Satellite Separation Process of a Typical Launch Vehicle. The Journal of Defense Modeling and Simulation 9:4, 369-382. doi:1177/1548512911401939
Koneru, S., Srinath, A., Nageswara Rao, B. (2022). Multiobjective optimization for the optimal heat pipe working parameters based on Taguchi’s design of experiments. Heat Transf. 51:3, 2510-2523. https://doi.org/10.1002/htj.22410.
Sanjeevannavar, M.B., Banapurmath, N.R., Soudagar, M.E.M., Atgur, V., Hossain, N., Mujtaba, M.A., Yunus Khan, T.M., Nageswar Rao, B., Ismail, K.A., Elfasakhany, A. (2022). Performance indicators for the optimal BTE of biodiesels with additives through engine testing by the Taguchi approach. Chemosphere 288: 132450. https://doi.org/10.1016/j.chemosphere.2021.132450.
Satyanarayana, G., Narayana, K.L. & Nageswara Rao, B. (2018).Identification of optimum laser beam welding process parameters for E110 zirconium alloy butt joint based on Taguchi-CFD simulations. Lasers Manuf. Mater. Process. 5, 182–199. https://doi.org/10.1007/s40516-018-0061-7
Rajyalakshmi, K., Nageswara Rao, B. (2019). Modified Taguchi approach to trace the optimum GMAW process parameters on weld dilution for ST-37 steel plates. ASTM Int. J. Test. Eval. 47(4), 3209–3223. DOI: 1520/JTE20180617
Satyanarayana, G., Narayana, K.L., Nageswara Rao, B. (2021). Incorporation of Taguchi approach with CFD simulations on laser welding of spacer grid fuel rod assembly. Mater. Sci. Eng. B 269:115182 (2021). https://doi.org/10.1016/j.mseb.2021.115182
Satyanarayana, G., Narayana, K.L., Nageswara Rao, B. (2019). Optimal laser welding process parameters and expected weld bead profile for P92 steel. SN Appl. Sci. 1:1291. https://doi.org/10.1007/s42452-019-1333-3.
Dharmendra, B.V., Kodali, S.P., Nageswara Rao, B.: A simple and reliable Taguchi approach for multi-objective optimization to identify optimal process parameters in nano-powder-mixed electrical discharge machining of INCONEL800 with copper electrode. HELIYON 5, e02326 (2019). https://doi.org/10.1016/j.heliyon.2019.e02326.
Dharmendra, B.V., Kodali, S.P., Nageswara Rao, B. (2020). Multi objective optimization for optimum abrasive water jet machining process parameters of Inconel718 adopting the Taguchi approach. Multidiscip. Model. Mater. Struct. 16:2, 306–321. https://doi.org/10.1108/MMMS-10-2018-0175
Sastry, K.S.S., Kumar, K.V.D.S.R.M., Priyanka, M., Ram, M.R., Nageswara Rao, B. (2017). Application of Taguchi approach to seek optimum drilling parameters for woven fabric carbon fibre/epoxy laminates. MAYFEB J. Mech. Eng. 1, 29–37.
Rajyalakshmi, K., Nageswara Rao, B. (2019). Expected range of the output response for the optimum input parameters utilizing the modified Taguchi approach. Multidiscip. Model. Mater. Struct. 15:2, 508–522. https://doi.org/10.1108/MMMS-05-2018-0088
Buddi, T., Singh, S.K., Nageswara Rao, B. (2018). Optimum process parameters for plywood manufacturing using soya meal adhesive. Mater. Today Proc. 5, 18739–18744. https://doi.org/10.1016/j.matpr.2018.06.220
Danthala, S., Srinivasa Rao, S., Nageswara Rao, B., Mannepalli, K.(2021). Multi-objective optimization with modified Taguchi approach to specify optimal robot spray painting process parameters. Int. J. Nonlinear Anal. Appl. (IJNAA) 12:2, 1163-1174. https://doi.org/10.22075/ijnaa.2021.5193.
Miladinovic, S., Velickovic, S., Loknath, D., Karthik, K., Nageswara Rao, B. (2020). Parameters identification and minimization of safety coefficient for surface durability of internal planetary gear using the modified Taguchi approach. TEST Eng. Manag. 83, 25108–25116.
Prakash, K.S., Gopal, P.M., Karthik, S. (2020). Multi-objective optimization using Taguchi based grey relational analysis in turning of rock dust reinforced aluminum MMC. Measurement 157:107664. https://doi.org/10.1016/j.measurement.2020.107664
Mohamed, M.A., Manurung, Y.H., Berhan, M.N. (2015). Model development for mechanical properties and weld quality class of friction stir welding using multi-objective Taguchi method and response surface methodology. J. Mech. Sci. Technol. 29:6, 2323–2331. https://doi.org/10.1007/s12206-015-0527-x
Muni Tanuja, A., Kumar, A., Nageswara Rao, B. (2022). Review on the Application of CGP to Improve AZ31 Mg Alloy Properties. In: Deepak, B.B.V.L., Parhi, D., Biswal, B., Jena, P.C. (eds) Applications of Computational Methods in Manufacturing and Product Design. Lecture Notes in Mechanical Engineering. Springer, Singapore. https://doi.org/10.1007/978-981-19-0296-3_21
Muni Tanuja, A., Tanya, B., Nageswara Rao, B. (2023). Multi-objective optimization basing modified Taguchi method to arrive the optimal die design for CGP of AZ31 magnesium alloy, International Journal on Interactive Design and Manufacturing (IJIDeM), Springer Nature. https://doi.org/10.1007/s12008-022-01176-6
Muni Tanuja, A., Tanya,, Nageswara Rao,B.(2023).Utilisation of fuzzy logic and genetic algorithm to seek optimal corrugated die design for CGP of AZ31 magnesium alloy,Advances in Materials and Processing Technologies,DOI: 10.1080/2374068X.2023.2192135
Dharmendra, B.V., Kodali, S.P.; Nageswara Rao, B. (2020). Multi-objective optimization for optimum abrasive water jet machining process parameters of Inconel718 adopting the Taguchi approach. Multidiscipline Modeling in Materials and Structures, 16:2, 306-321. DOI:10.1108/MMMS-10-2018-0175
Prakash, K.S., Gopal, P., Karthik, S. (2020). Multi-objective optimization using Taguchi based grey relational analysis in turning of rock dust reinforced aluminum MMC. Measurement, 157:107664. https://doi.org/10.1016/j.measurement.2020.107664

Conference Open Access Original Research

Journal of Polymer and Composites

ISSN: 2321–2810

Volume	11
Special Issue	08
Received	October 19, 2023
Accepted	October 30, 2023
Published	February 16, 2024

Not A Member?

Join Us

Submit Manuscript

Submit Topics

Initiatives

Guidelines For

Further Information

Corporate Office

STM Journals,
An imprint of Consortium E-learning network Pvt. Ltd.
A-118, 1st Floor, Sector-63, Noida, U.P. India,
Pin-201301
(Tel) (+91) 0120- 4781 200
(Mob) (+91) 9810078958, +919667725932
E-mail: [email protected]

WEBSITE DISCLAIMER

Last updated: 2022-06-15

The information provided by STM Journals (“Company”, “we”, “our”, “us”) on https://journals.stmjournals.com/ (the “Site”) is for general informational purposes only. All information on the Site is provided in good faith, however, we make no representation or warranty of any kind, express or implied, regarding the accuracy, adequacy, validity, reliability, availability, or completeness of any information on the Site.

UNDER NO CIRCUMSTANCE SHALL WE HAVE ANY LIABILITY TO YOU FOR ANY LOSS OR DAMAGE OF ANY KIND INCURRED AS A RESULT OF THE USE OF THE SITE OR RELIANCE ON ANY INFORMATION PROVIDED ON THE SITE. YOUR USE OF THE SITE AND YOUR RELIANCE ON ANY INFORMATION ON THE SITE IS SOLELY AT YOUR OWN RISK.

EXTERNAL LINKS DISCLAIMER

The Site may contain (or you may be sent through the Site) links to other websites or content belonging to or originating from third parties or links to websites and features. Such external links are not investigated, monitored, or checked for accuracy, adequacy, validity, reliability, availability, or completeness by us.

WE DO NOT WARRANT, ENDORSE, GUARANTEE, OR ASSUME RESPONSIBILITY FOR THE ACCURACY OR RELIABILITY OF ANY INFORMATION OFFERED BY THIRD-PARTY WEBSITES LINKED THROUGH THE SITE OR ANY WEBSITE OR FEATURE LINKED IN ANY BANNER OR OTHER ADVERTISING. WE WILL NOT BE A PARTY TO OR IN ANY WAY BE RESPONSIBLE FOR MONITORING ANY TRANSACTION BETWEEN YOU AND THIRD-PARTY PROVIDERS OF PRODUCTS OR SERVICES.

PROFESSIONAL DISCLAIMER

The Site can not and does not contain medical advice. The information is provided for general informational and educational purposes only and is not a substitute for professional medical advice. Accordingly, before taking any actions based on such information, we encourage you to consult with the appropriate professionals. We do not provide any kind of medical advice.

Content published on https://journals.stmjournals.com/ is intended to be used and must be used for informational purposes only. It is very important to do your analysis before making any decision based on your circumstances. You should take independent medical advice from a professional or independently research and verify any information that you find on our Website and wish to rely upon.

THE USE OR RELIANCE OF ANY INFORMATION CONTAINED ON THIS SITE IS SOLELY AT YOUR OWN RISK.

AFFILIATES DISCLAIMER

The Site may contain links to affiliate websites, and we may receive an affiliate commission for any purchases or actions made by you on the affiliate websites using such links.

TESTIMONIALS DISCLAIMER

The Site may contain testimonials by users of our products and/or services. These testimonials reflect the real-life experiences and opinions of such users. However, the experiences are personal to those particular users, and may not necessarily be representative of all users of our products and/or services. We do not claim, and you should not assume that all users will have the same experiences.

YOUR RESULTS MAY VARY.

The testimonials on the Site are submitted in various forms such as text, audio, and/or video, and are reviewed by us before being posted. They appear on the Site verbatim as given by the users, except for the correction of grammar or typing errors. Some testimonials may have been shortened for the sake of brevity, where the full testimonial contained extraneous information not relevant to the general public.

The views and opinions contained in the testimonials belong solely to the individual user and do not reflect our views and opinions.

ERRORS AND OMISSIONS DISCLAIMER

While we have made every attempt to ensure that the information contained in this site has been obtained from reliable sources, STM Journals is not responsible for any errors or omissions or the results obtained from the use of this information. All information on this site is provided “as is”, with no guarantee of completeness, accuracy, timeliness, or of the results obtained from the use of this information, and without warranty of any kind, express or implied, including, but not limited to warranties of performance, merchantability, and fitness for a particular purpose.

In no event will STM Journals, its related partnerships or corporations, or the partners, agents, or employees thereof be liable to you or anyone else for any decision made or action taken in reliance on the information in this Site or for any consequential, special or similar damages, even if advised of the possibility of such damages.

GUEST CONTRIBUTORS DISCLAIMER

This Site may include content from guest contributors and any views or opinions expressed in such posts are personal and do not represent those of STM Journals or any of its staff or affiliates unless explicitly stated.

LOGOS AND TRADEMARKS DISCLAIMER

All logos and trademarks of third parties referenced on https://journals.stmjournals.com/ are the trademarks and logos of their respective owners. Any inclusion of such trademarks or logos does not imply or constitute any approval, endorsement, or sponsorship of STM Journals by such owners.

CONTACT US

Should you have any feedback, comments, requests for technical support, or other inquiries, please contact us by email: [email protected].