Experimental evaluation onto the machinability of sustainable Al/SiC/Gr hybrid composite using grey relational analysis

Abstract

The utilization of Aluminium Matrix Composites (AMCs) has undergone a tremendous increase due to its distinct characteristics. However, the inclusion of reinforcement in the aluminium matrix reduces its machinability due to the presence of hard reinforcements in it. This research article refers to the fabrication and evaluation of machining behaviour of newly developed SiC and Graphite reinforced AMC. AMCs were developed through the stir casting route. Al 6061 alloy was selected as the base matrix, which was reinforced with silicon carbide Graphite. Uncoated and multiple layer coated carbide tools were used to evaluate the turning of AMC at various speeds (60, 90 and 120 m/min) and feeds (0.07, 1.0 and 0.13 mm/rev) in the form of surface roughness, material cutting rate and tool wear rate by employing Grey Relational Analysis. Results indicated that feed rate is the highly prominent parameters affecting process performance, followed by spindle speed and tool type. The optimum set of input conditions is to turn Al-SiC-Gr hybrid AMC at a speed of 120 m/min feed of 0.1 mm/rev with a coated carbide tool. The predicted value of Grey Relational Grades was also determined to validate results.