Experimental modelling and optimisation of electrochemical surface grinding of hybrid metal matrix composite

Abstract

ABSTRACT The demand of hybrid-metal-matrix composites (HMMCs) is rising continuously in various industries such as aerospace, automobile and biomedical. Therefore, effective machining of HMMCs is essential for their productive utilisation. However, machining processes are usually not feasible for shaping this composite due to inherent properties of matrix and reinforcing material, and melting of reinforcement particles. In the present work, a hybrid Electro-Chemical Surface Grinding (ECSG) setup has been developed by combining the Electro-Chemical Machining and Mechanical Grinding action. The process applied on Al-SiC-Gr composite, which is a key member of HMMC family. It is a better alternative for many parts like piston and piston ring in automobile industries. Central composite design-based Response Surface Methodology has been used for experimental modelling, response prediction and optimisation. The effects of significant control factors such as applied voltage, electrolyte concentration, wheel speed, table speed and electrolyte flow rate on material removal rate (MRR) and surface roughness (SR) have been studied. The results revealed that electrolyte concentration and applied voltage are most significant factors for both MRR as well as SR. Genetic algorithm-based optimisation results confirm 45% and 38% improvements in MRR and surface finish.