Multi-objective optimization of AAJM process parameters for cutting of B4C/Gr particles reinforced Al 7075 composites using RSM-TOPSIS approach

Murahari Kolli,Dasari Sai Naresh,A V S Ram Prasad

doi:10.1007/s42452-021-04699-x

Abstract

The present study deals with the machining of hybrid Al 7075/B4C/Gr composite using Abrasive Aqua Jet Machining. The effects of selected input factors, i.e., water jet pressure (WJP), stand-off distance (SOD), and traverse speed (TS) on the performance characteristics, namely taper angle (TA), surface roughness (Ra), and the material removal rate (MRR) are investigated. The experimental runs and test strategies are formulated using the Response Surface Methodology-Central Composite Design approach. Analysis of Variance (ANOVA) was used to examine the effect of input factors and their interactions with performance characteristics. MRR, Ra, and TA optimum condition and mathematical equations were also developed. Further, the multi-optimization method “Technique for Order of Preference by Similarity to Ideal Solution” is considered to find out the best combinations of input factors for optimized output factors on the hybrid composite. The ANOVA results confirm that among the input factors, WJP and SOD are the most significant factors, and the percentage distribution of input factors are found to be jet pressure (55.21%), stand-off distance (23.36%), and traverse speed (2.56%). The multi-objective optimum conditions of the input factors are WJP (A1) 210 bar, SOD (B1), and TS (C3) 30 mm/min, that produce optimal values of the considered responses, i.e., MRR up to 4.8703 mm3/min, Ra up to 3.57 μm and TA up to 0.189°. The TA has improved by 49.6% through the multi-objective optimum results when compared with single parameter optimized results.Article HighlightsHybrid Al7075/B4C/Gr composite fabricated through the rotary stir casting techniqueExperimental planning and designing layouts using Response Surface Methodology scheme and mathematical equations are produced with Design Expert 11.0.The best TA was obtained by RSM-TOPSIS approach, found at a lower WJP and SOD and a higher TS.

Highlights

A significant challenge in the development of materials with high strength to weight ratio in material sciences and engineering remains even today
The main objective of the study is the multiparametric optimization of AAJM process parameters using the RSM-CCD-TOPSIS approach
The first part deals with single performance characteristics optimization (3.1), and the second part discusses multiple objective parameters optimization using the TOPSIS approach (3.2) and the final part verifies and discusses the conformation

Summary

Introduction

A significant challenge in the development of materials with high strength to weight ratio in material sciences and engineering remains even today. Machining of HMMCs is a very challenging task in the present scenario because of the hard, reinforced, abrasive particles present in their matrix. They pose significant difficulties in machining through traditional machining processes [4]. None of the conventional machining methods, when used to machine HMMC’s, can yield high dimensional accuracies and can become very expensive to produce such results Apart from these reasons, defects like cracks and voids on the machined surface of HMMC are commonly found in samples machined through conventional routes. The replacement for machining HMMCs with unconventional machining methods such as laser beam machining, plasma machining, water jet machining, electrical discharge machining, wire electrical discharge machining, etc. is being widely explored [7]

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Conclusion