Multi-objective optimization of process parameters involved in micro-finishing of Al/SiC MMCs by abrasive flow machining process

Abstract

It is hard to finish small slots in composite materials which have wide applications nowadays in aerospace, automobile and medical. Abrasive flow machining is a process that is suitable for such type of operations. In this paper, by using abrasive flow machining, investigation of SiC Metal Matrix Composites (MMCs) with aluminum as base material has been done. Material removal rate and change in surface roughness (ΔRa) are taken as response parameters. Response surface methodology has been applied to find out the effect of input parameters like fluid pressure, percentage of oil in media, grit size, concentration of abrasives, workpiece material and number of cycles on response parameters. Box–Behnken design has been preferred. Response parameters have been optimized using the desirability approach in response surface methodology. The significance of different parameters is identified using analysis of variance. An optimum combination of parameters is designed for the process. Furthermore, specimens were examined and analyzed using scanning electron microscope and X-ray diffraction techniques.