Abstract
To fulfil the present-day technological requirements of light weight materials with higher strength, hardness, stiffness, wear and corrosion resistance properties, aluminium metal matrix composites (Al-MMCs) now appear as viable alternative materials in many of the manufacturing industries. Hybrid Al-MMCs with heterogeneous reinforcement elements are now gradually substituting the single-reinforced composites due to their more improved physical and wear resistance properties. In this paper, hybrid Al-MMCs are developed using silicon carbide, fly ash and bagasse ash as the reinforcements, and an attempt is put forward to optimize its drilling operation treating spindle speed, feed rate and drill diameter as the input parameters, and material removal rate (MRR) and average surface roughness (Ra) as the responses. To overcome the drawbacks of standalone Taguchi methodology, this paper presents the applications of four simple multi-objective optimization techniques, i.e. grey relational analysis (GRA), multiple response signal-to-noise (MRSN) ratio, weighted signal-to-noise (WSN) ratio and technique for order of preference by similarity to ideal solution (TOPSIS) for identification of the optimal parametric combinations of the said drilling operation. It is observed that most of the adopted approaches recommend higher spindle speed (255 rpm), feed rate (82 mm/rev) and drill diameter (12 mm) as the optimal settings of the drilling parameters for achieving compromised values of both the responses when equal importance is assigned to them. Effects of varying weights allotted to the responses on the derived optimal parametric combinations are also studied along with confirmatory experiments.
Similar content being viewed by others
References
Grilo, J., Carneiro, V.H., Teixeira, J.C., Puga, H.: Manufacturing methodology on casting-based aluminium matrix composites: a systematic review. Metals 11(3), 436 (2021)
Emiru, A.A., Sinha, D.K., Kumar, A., Yadav, A.: Fabrication and characterization of hybrid aluminium (Al6061) metal matrix composite reinforced with SiC, B4C and MoS2 via stir casting. Int. J. Metalcast. (2022). https://doi.org/10.1007/s40962-022-00800-1
Budapanahalli, S.H., Mallur, S.B., Patil, A.Y., Alosaimi, A.M., Khan, A., Hussein, M.A., Asiri, A.M.: A tribological study on the effect of reinforcing SiC and Al2O3 in Al7075: applications for spur gears. Metals 12(6), 1028 (2022)
Nturanabo, F., Masu, L., Kirabira, J. B. (2019) Novel applications of aluminium metal matrix composites. In: Aluminium Alloys and Composites, KO Cooke (ed) Intech Open, 263–289
Kumar, K., Dabade, B.M., Wankhade, L.N.: Experimental investigation and parameters optimization for better wear performance at elevated temperature of aluminium composites using RSM and GRA. Int. J. Interact. Des. Manuf. (2022). https://doi.org/10.1007/s12008-022-00899-w
Bhowmik, A., Dey, D., Biswas, A.: Comparative study of microstructure, physical and mechanical characterization of SiC/TiB2 reinforced aluminium matrix composite. SILICON 13(6), 2003–2010 (2021)
Bhowmik, A., Dey, D., Biswas, A.: Characteristics study of physical, mechanical and tribological behaviour of SiC/TiB2 dispersed aluminium matrix composite. SILICON 14(3), 1133–1146 (2022)
Darji, Y., Patel, D.: Effect of nano reinforcement on aluminium metal matrix composites: a review. ECS Trans. 107(1), 939–946 (2022)
Tekale, S.N., Dolas, D.R.: Study of fabrication methods and various reinforcements with aluminium for automotive application—a review. Mater. Today Proc. 62(6), 2768–3773 (2022)
Kurbet, R., Basavaraj, Amruth CM, Jayasimha SLN (2022) Effect of ceramic particles on AMMC through stir casting method—a review. In: Proceedings of 4th International Conference on Inventive Material Science. Applications Advances in Sustainability Science and Technology. Springer, Singapore 373–388
Prakash, C., Senthil, P., Manikandan, N., Palanisamy, D.: Machinability investigations of aluminium metal matrix composites (LM26 + graphite + flyash) by using wire electrical discharge machining process. In: Recent Advances in Materials and Modern Manufacturing, pp. 983–991. Springer, Singapore (2022)
Umanath, K., Nithyanandhan, T., Ajayan, A., Devika, D., Prasath, M.G., Kumar, S.A., Ganeesh, R.: Machinability study of aluminium 6082 reinforced with boron carbide and titanium by stir casting method using abrasive water jet machining process. Eng. Res. Express 4(1), 015011 (2022)
Chakravarthy, V.V., Rajmohan, T., Vijayan, D., Palanikumar, K.: Sustainable drilling of nano SiC reinforced Al matrix composites using MQL and cryogenic cooling for achieving the better surface integrity. SILICON 14(4), 1787–1805 (2022)
Liu, C., Wang, Z., Gao, L., Zhang, X., Wang, G., Yang, T., Du, Y.: A novel tool wear modeling method in drilling of particle reinforced metal matrix composite. Int. J. Adv. Manuf. Technol. 119(11), 7089–7107 (2022)
Babu, S.S., Dhanasekaran, C., Anbuchezhiyan, G., Palani, K.: Parametric analysis on drilling of aluminium alloy hybrid composites reinforced with SiC/WC. Eng. Res. Express 4(2), 025036 (2022)
Daniel, S.A.A., Kumar, R., Vijay Ananth, S., Pugazhenthi, R.: Multi-objective optimization of drilling of Al5059-SiC-2% MoS2 composites using NSGA-II. Mater. Today Proc. 22, 853–857 (2020)
Udaya Prakash, J., Perumal, S., Moorthy, T.V.: Optimization of machining parameters in drilling of aluminium matrix composites using Taguchi technique. Int. J. Appl. Eng. Res. 10(68), 526–529 (2015)
Ravindranath, V.M., Shiva Shankar, G.S., Basavarajappa, S., Suresh, R.: Optimization of Al/B4C and Al/B4C/Gr MMC drilling using Taguchi approach. Mater. Today Proc. 4, 11181–11187 (2017)
Juliyana, S.J., Udaya Prakash, J.: Optimization of burr height in drilling of aluminium matrix composites (LM5/ZrO2) using Taguchi technique. Adv. Mater. Process. Technol. 8, 417–426 (2022)
Rubi, C.S., Udaya Prakash, J., Rajkumar, C.: Optimization of process parameters using Taguchi technique for drilling aluminium matrix composites (LM6/B4C). Mater. Sci. Eng. 912, 032016 (2020)
Juliyana, S.J., Udaya Prakash, J.: Drilling parameter optimization of metal matrix composites (LM5/ZrO2) using Taguchi technique. Mater. Today Proc. 33, 3046–3050 (2020)
Rajmohan, T., Palanikumar, K., Kathirvel, M.: Optimization of machining parameters in drilling hybrid aluminium metal matrix composites. Trans. Nonferrous Metals Soc. China 22, 1286–1297 (2012)
Singh, S., Singh, I., Dvivedi, A.: Multi objective optimization in drilling of Al6063/10% SiC metal matrix composite based on grey relational analysis. Proc. I Mech. E Part B J. Eng. Manuf. 227(12), 1767–1776 (2013)
Singh, H., Kamboj, A., Kumar, S.: Multi response optimization in drilling Al6063/SiC/15% metal matrix composite. Int. J. Mech. Mech. Eng. 8(4), 309–314 (2014)
Elango, M., Annamalai, K.: Machining parameter optimization of Al/SiC/Gr hybrid metal matrix composites using ANOVA and grey relational analysis. FME Trans. 48, 173–179 (2020)
Rubi, C.S., Udaya Prakash, J.: Drilling of hybrid aluminum matrix composites using grey-Taguchi method. INCAS Bull. 12(1), 167–174 (2020)
Udaya Prakash, J., Rubi, C.S., Rajkumar, C., Juliyana, S.J.: Multi-objective drilling parameter optimization of hybrid metal matrix composites using grey relational analysis. Mater. Today Proc. 39, 1345–1350 (2021)
Rubi, C.S., Prakash, J.U., Čep, R., Elangovan, M.: Optimization of process variables in the drilling of LM6/B4C composites through grey relational analysis. Materials 15, 4860 (2022)
Rubi, C.S., Prakash, J.U., Rajkumar, C., Mohan, A., Muthukumarasamy, S.: Optimization of process variables in drilling of LM6/fly ash composites using grey-Taguchi method. Mater. Today Proc. 62(10), 5894–5898 (2022)
Padma, P., Mayee, M. C.: Application of a multi-criteria-decision-making (MCDM) method of TOPSIS in drilling of AA6082. In: International Journal of Management, Technology and Engineering 8(VIII): 1771–1781 (2018)
Balasubramanian, S., Asvath, G., Sivam, S.P.S.S.: Application of multi criteria decision making of setting input process parameters for drilled product quality of Al Si7 Cu4. Mater. Sci. Eng. 912, 032082 (2020)
Paramasivam, S.S.S.S., Durai, K., Natarajan, H.: Taguchi additive ratio assessment (ARAS) method in multi-criteria decision making: A case study for treated drill tools performance. Int. J. Modern Manuf. Technol. XI I(1), 114–124 (2020)
Panchagnula, K.K., Sharma, J.P., Kalita, K., Chakraborty, S.: CoCoSo method-based optimization of cryogenic drilling on multi-walled carbon nanotubes reinforced composites. Int. J. Interact. Des. Manuf. 17, 279–297 (2023)
Kayaroganam, P., KrishnanV, N.E., Natarajan, S., Muthusamy, K.: Drilling parameters analysis on in-situ Al/B4C/mica hybrid composite and an integrated optimization approach using fuzzy model and non-dominated sorting genetic algorithm. Metals 11, 2060 (2021)
Kundiya, R., Bhagwat, S.: Application of Jaya algorithm in optimization of mechanical drilling of metal matrix composite. Int. Res. J. Mod. Eng. Technol. Sci. 4(6), 133–140 (2022)
Phadke, M.S.: Quality Engineering Using Robust Design. Prentice-Hall, Englewood Cliffs (1989)
Ross, J.: Taguchi Techniques for Quality Engineering. McGraw-Hill, Singapore (1996)
Gauri, S.K., Chakraborty, S.: A study on the performance of some multi-response optimisation methods for WEDM processes. Int. J. Adv. Manuf. Technol. 49, 155–166 (2010)
Kuo, Y., Yang, T., Huang, G.-W.: The use of grey relational analysis in solving multiple attribute decision-making problems. Comput. Ind. Eng. 55(1), 80–93 (2008)
Hwang, C., Yoon, K.: Multiple Attribute Decision-making: Methods and Applications. Springer-Verlag, New York (1981)
Jain, P.K., Soni, S.C., Baredar, P.V.: Review on machining of aluminium metal matrix composites. Mater. Sci. Res. India 11(2), 114–120 (2014)
Ficici, F.: Evaluation of surface roughness in drilling particle-reinforced composites. Adv. Compos. Lett. 29, 1–11 (2020)
Demir, Z.: An experimental investigation of the effects of point angle on the high-speed steel drills performance in drilling. Meas. Control 51(9–10), 417–430 (2018)
Amran, M.A., Salmah, S., Hussein, N.I.S., Izamshah, R., Hadzley, M., Sivaraos, K.M.S., Sulaaiman, M.A.: Effects of machine parameters on surface roughness using response surface method in drilling process. Procedia Eng. 68, 24–29 (2013)
Funding
No external funding is required for this research study.
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The authors declare no competing interests.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Sapkota, G., Ghadai, R.K., Das, S. et al. A comparative study on multi-objective optimization of drilling of hybrid aluminium metal matrix composite. Int J Interact Des Manuf 17, 3177–3187 (2023). https://doi.org/10.1007/s12008-023-01390-w
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12008-023-01390-w