Optimization of machining parameters in CNC turning of AA6061-B4C-CNT hybrid composites using Grey-fuzzy method

Abstract

Aluminium hybrid composites and its machining receives a great attention due to their superior properties like good strength to weight ratio, good castability, machinability, and low cost, suitable for various applications in automotive and aerospace industries. CNC turning is considered as an ideal method for machining of aluminium hybrid composites. Nevertheless, the parameters of turning of aluminium hybrid composites need to be optimized for better and precise machining. Also, the presence of solid lubricants such as Carbon nanotube, Graphite, hexagonal Boron Nitride etc. promotes the machinability of aluminium hybrid composites. In this study, CNC turning on AA6061 matrix based hybrid composites reinforced with Boron carbide (5-15 vol.%) and Carbon nanotube (15 vol.%) was performed. Cutting Speed (rpm):60-180, feed (mm/rev): 0.10-0.20, depth of cut (mm): 0.50-1.00 and percentage of B4C (vol.%) 5-15 were the controlling parameters and responses namely tangential force (N), cutting power (W) and tool wear (mm3/min) were considered for the optimization. Experimental design was made as per Taguchi’s L27 orthogonal array and Grey-fuzzy analytical tool was applied for the optimization. The optimal setting for turning operation on this hybrid composite using Grey-fuzzy analysis were 120 rpm, 0.20 mm/rev, 0.5 mm and 15 vo.% for cutting speed, feed, depth of cut and reinforcement respectively.