Optimization of Abrasive Water Jet Machining Parameters on AA6061/B4C/hBN Hybrid Composites using Grey-RSM

Abstract

Aluminium Matrix Hybrid Composites (AMHCs) possess an excellent combination of physical and mechanical properties suitable for a variety of applications in automobile and aerospace industries. Addition of solid lubricant hexagonal Boron Nitride (hBN) reduces the complexity in machining of aluminium hybrid composites. Abrasive Water Jet Machining (AWJM) is a non-traditional technique applied for the machining of alloys and composites, due to its better cutting performances. In this work, AA6061 matrix hybrid composites reinforced with B4C (5, 10 and 15vol.%) and hBN (15vol.%) were developed through liquid metallurgy route. The composite were then machined using AWJM. Process parameters considered were abrasive flow rate, water pressure, traverse speed, percentage of reinforcement and mesh size over the responses Kerf Taper Angle (KTA) and Surface roughness (Ra). The experimental design was based on L27 orthogonal array and Grey-RSM analytical tool was applied for optimization. The optimal values of parameter setting for AWJM machining process using Grey RSM methodology were 340 g/min, 200 MPa, 60.06 mm/min, 5.01% and 80 for abrasive flow rate, water pressure, traverse speed, percentage of reinforcement and mesh size were respectively.