Optimization of machining parameters in drilling of LM6/B4C/Fly ash hybrid composites

Abstract

Metal matrix composites (MMCs), innovative replacements for traditional materials, are currently achieving a growing trend in engineering and research for operations like aviation, nuclear power, and automotive. Machining of MMCs makes it challenging to get good dimensional accuracy, surface finish and lower tool wear. Drilling is a necessary and immensely useful tool for component assembly in the manufacturing sector. As a result, optimization of drilling process variables is unavoidable. The fundamental purpose of this study is to use the stir casting technique to manufacture LM6/B4C/Fly ash composites with 3, 6 and 9 wt.% of second phase materials. Taguchi's design of experiments strategy was used to drill with three levels of feed rate (F), spindle speed (S), drill material (D) and percentage of reinforcement (R) as input process parameters. Optimization of drilling variables for attaining lower surface roughness (SR) and burr height (BH) using single objective approach. The optimum process variable achieved for surface roughness is F1S3D3R2, i.e., 50 mm/min, 3000 rpm, TiN-coated drill bit and 6 wt.% of reinforcements (B4C and Fly-ash) and for burr height is F1S3D3R3, i.e., 50 mm/min, 3000 rpm, TiN-coated drill bit and 9 wt.% of reinforcements.