Investigation and optimization of machining parameters in electrochemical machining of aluminium metal matrix composites

Abstract

Metal matrix composites (MMCs) have been increasingly used in industries, nuclear plant, and automobiles due to their superior properties compared to other alloys, and that is owing to the tough and abrasive hard reinforced particles. It’s complicated to machine hard materials by traditional processes methods, therefore the present study focused on the investigation of parameters in electrochemical machining (ECM) like electrolyte concentration (EC), voltage(V), and Inter-electrode gap (IEG) on the radial over cut (ROC) and material removal rate (MRR) in the ECM of Al-7.5%B₄C. Stir casting method was used to fabricate metal matrix composites. Based on Taguchi design, the process parameters were optimized. A Multiple Regression Model (MRM) was employed as model for radial over cut and material removal rate. The mathematical model was examined using analysis of variance (ANOVA). The EC 10 g/L, V 10 v, and IEG 0.3 mm are the optimal parametric combination for ROC. Also, the EC 30 g/L, V 18 V, and IEG 0.2 mm are the optimal parametric combination for MRR.