Enhancing the geometric tolerance of aluminium hybrid metal matrix composite using EDM process

Abstract

A generous development of electrical discharge machining method has been stimulated in the province of metal matrix composites materials. In this extant work, the optimal condition for various output responses specifically circularity, cylindricity, perpendicularity and radial over cut are exposed by employing grey relational analysis procedure by optimizing the input process parameters alike pulse on time (Ton), peak current (I) and gap voltage (V). The Hybrid Metal Matrix Composite material is evolved by handling the stir casting approach and then machined by exploring the input parameters using L27 orthogonal array. From the consequences of grey relational grade, a response table was discovered to elect the optimal conditions of the individual parameter. The most contributing input parameter is current with 69.08%, which is determined from the ANOVA table. Finally, the optimal conditions which were acquired from the response table are peak current of 12 A, pulse on time of 50 µs and gap voltage of 30 V and also verified through an authentication test which illustrated that optimal process parameters are competently improved by 0.1452 when compared to the predicted parameter. The machined surface is analysed using a scanning electron microscope. The results palpated that the peak current increases the number of microvoids and size of the crater was increased and the poor surface finish was achieved.