Indian Journal of Engineering & Materials Sciences

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Performance evaluation and multi-response hybrid optimization of grinding assisted rotary disk ECDM during cutting of Al-6063 SiCp MMC


Affiliations
1 Department of Mechanical Engineering, JSS Academy of Technical Education, Noida 201 301, India
2 Industrial & Production Engineering Department, College of Technology, G.B. Pant University of Agriculture & Technology, Pantnagar 263 145, India
3 Mechanical Engineering Department, Indian Institute of Technology Bombay 400 076, India
4 Mechanical and Industrial Engineering Department, Indian Institute of Technology, Roorkee, Uttrakhand 247 667, India

The Metal Matrix Composites (MMCs) are being used in many applications, including aerospace, shipbuilding, and defence industries owing to their high strength to weight ratio. However, the machining of these materials is still challenging, necessitating advanced machining techniques. The current investigation aimed to analyze the performance of the grinding-assisted rotary disc-electrochemical discharge machining (GA-RD-ECDM) process during cutting Al-6063 SiCp MMC. Detailed experimentation was performed to study the energy interaction behavior and effect of input process variables viz. applied voltage, pulse on time, electrolyte concentration, and disc rotation speed on performance measures. The responses selected were taper, overcut (WOC), and Materials Removal Rate (MRR). The experimentation work was performed by adopting response surface methodology. Regression models were developed and statistically analyzed through analysis of variance (ANOVA). Eventually, the GA-RD-ECDM process was optimized using the VIKOR methodology of multi-criteria decision-making by considering accuracy and productivity simultaneously to obtain minimum taper and WOC and maximum MRR. The results of ANOVA revealed that input variables were statistically significant. Applied voltage most significantly affects the performance of the GA-RD-ECDM process performance. The optimal values of input process variables obtained by VIKOR method were applied voltage = 100 V, pulse-on time = 3 ms, Electrolyte concentration = 18% wt/vol. and disc rotation speed = 30 rpm. The present work can provide a productive solution for cutting of difficult-to-cut materials. Thus, in future, the GA-RD-ECDM process can be investigated for other advanced materials (i.e., glass, polymer composites and ceramics) for fabrication of microchannels for microfluidic applications.
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  • Performance evaluation and multi-response hybrid optimization of grinding assisted rotary disk ECDM during cutting of Al-6063 SiCp MMC

Abstract Views: 104  | 

Authors

Navin Kumar Jha
Department of Mechanical Engineering, JSS Academy of Technical Education, Noida 201 301, India
Sandeep Kumar
Industrial & Production Engineering Department, College of Technology, G.B. Pant University of Agriculture & Technology, Pantnagar 263 145, India
Rajendra Kumar Arya
Mechanical Engineering Department, Indian Institute of Technology Bombay 400 076, India
Akshay Dvivedi
Mechanical and Industrial Engineering Department, Indian Institute of Technology, Roorkee, Uttrakhand 247 667, India
Shivanna Rajesh
Department of Mechanical Engineering, JSS Academy of Technical Education, Noida 201 301, India

Abstract


The Metal Matrix Composites (MMCs) are being used in many applications, including aerospace, shipbuilding, and defence industries owing to their high strength to weight ratio. However, the machining of these materials is still challenging, necessitating advanced machining techniques. The current investigation aimed to analyze the performance of the grinding-assisted rotary disc-electrochemical discharge machining (GA-RD-ECDM) process during cutting Al-6063 SiCp MMC. Detailed experimentation was performed to study the energy interaction behavior and effect of input process variables viz. applied voltage, pulse on time, electrolyte concentration, and disc rotation speed on performance measures. The responses selected were taper, overcut (WOC), and Materials Removal Rate (MRR). The experimentation work was performed by adopting response surface methodology. Regression models were developed and statistically analyzed through analysis of variance (ANOVA). Eventually, the GA-RD-ECDM process was optimized using the VIKOR methodology of multi-criteria decision-making by considering accuracy and productivity simultaneously to obtain minimum taper and WOC and maximum MRR. The results of ANOVA revealed that input variables were statistically significant. Applied voltage most significantly affects the performance of the GA-RD-ECDM process performance. The optimal values of input process variables obtained by VIKOR method were applied voltage = 100 V, pulse-on time = 3 ms, Electrolyte concentration = 18% wt/vol. and disc rotation speed = 30 rpm. The present work can provide a productive solution for cutting of difficult-to-cut materials. Thus, in future, the GA-RD-ECDM process can be investigated for other advanced materials (i.e., glass, polymer composites and ceramics) for fabrication of microchannels for microfluidic applications.