DEPARTMENT OF MECHANICAL ENGINEERING

ADHIYAMAAN COLLEGE OF ENGINEERING, HOSUR

(AUTONOMOUS)

OPTIMIZATION OF PROCESS PARAMETERS IN TURNING

OF ALUMINIUM HYBRID COMPOSITE BY USING TAGUCHI
METHOD
Project done by
J. M. MOHAMMED KASHIF(AC18MEDOO2)

Under the Guidance

Project Guide of
Dr.S.V.Suresh Babu, M.E,Ph.D.
Head of the Department
Department of Mechanical Engineering
Adhiyamaan College of Engineering
Hosur – 635 109
 OPTIMIZATION OF PROCESS PARAMETERS IN TURNING OF ALUMINIUM HYBRID
COMPOSITE BY TAGUCHI METHOD
OBJECTIVES

1. To prepare the Al-SiC composites by using Centrifugal

casting process and to optimize the effect of process
parameters such as cutting temperature, surface
roughness, chip formation and tool wear in turning
operation.

2. To study the microstructure of the machined surface by

using Scanning Electron Microscope(SEM).
 OPTIMIZATION OF PROCESS PARAMETERS IN TURNING OF ALUMINIUM HYBRID
COMPOSITE BY TAGUCHI METHOD
INTRODUCTION

 Aluminium composite are generally difficult to machine,

because of the abrasive characteristics of the reinforced
particulates.
 It has poor machinability such as excessive tool wear
and fracturing of the reinforcement particles on machined
surface.
 The machinability of aluminium composites can be
improved by appropriate selection of the reinforcing
phase, its volume fraction, size, and morphology as well
as the composition and hardness of the matrix material.
 MULTI RESPONSE OPTIMIZATION OF PROCESS PARAMETERS IN TURNING OF
ALUMINIUM HYBRID COMPOSITE
ALUMINIUM 5083 ALLOY

5083 aluminium alloy is a very high strength aerospace

aluminium and is commonly used in applications where the
strength of the material is critical and where the need for good
corrosion resistance is important.
It is characterised by its:
High yield strength
Good corrosion resistance
High tensile strength
 OPTIMIZATION OF PROCESS PARAMETERS IN TURNING OF ALUMINIUM HYBRID
COMPOSITE
BORON CARBIDE (B4C)

Boron carbide (B4C) is an extremely hard material used

in tank armor , bullet proof vests, and numerous industrial
applications. It is one of the hardest materials known,
behind cubic boron nitride and diamond.
Boron carbide is characterised by its:
Extreme hardness
Good chemical resistance
Good nuclear properties
Low density
SILICON CARBIDE
 OPTIMIZATION OF PROCESS PARAMETERS IN TURNING OF ALUMINIUM HYBRID
COMPOSITE
GRAPHITE (Gr)

Graphite is a native element mineral found in metamorphic

and igneous rocks. Graphite is extremely soft, cleaves with very
light pressure, and has a very low specific gravity.
Graphite is characterised by its:
High thermal stability
Good chemical inertness
Good nuclear properties
High strength
High thermal conductivity
OPTIMIZATION OF PROCESS PARAMETERS IN TURNING OF ALUMINIUM HYBRID
COMPOSITE BY TAGUCHI METHOD
LITERATURE SURVEY

AUTHORS C.G.Sozhamannan et al.(2017)

MATERIAL Al 6061 reinforced with TiCp (3%) and Gr (10%)
COMPOSITION
MANUFACTURING This mixture is manufactured by stir casting technique.
METHOD
PROPERTIES STUDIED Tool wear and surface roughness

EXPERIMENTATION The sample is subjected to turning operation.

EQUIPMENTS USED Scanning Electron Microscope (SEM), Tool makers microscope.

CONCLUSION  The surface quality decreases at lower speed and feed rate with
higher depth of cut and higher surface quality for low speed and
high depth of cut and feed rate.
 There is a sudden increase in flank wear for the feed rate of
0.5mm at speed of 600rpm and gradual increase of flank wear
at feed rate of 0.75mm of speed 700rpm.
 OPTIMIZATION OF PROCESS PARAMETERs IN TURNING OF ALUMINIUM HYBRID
COMPOSITE BY TAGUCHI METHOD
LITERATURE SURVEY

AUTHORS V.M.Ravindranath et al.(2016)

MATERIAL Al 2219-B4C-Gr
COMPOSITION
MANUFACTURING This mixture is manufactured by stir casting technique.
METHOD
PROPERTIES STUDIED Cutting speed and feed

EXPERIMENTATION The parameters are optimized by Taguchi approach

EQUIPMENTS USED CNC milling machine

CONCLUSION  Thrust force decreases with increase in spindle speed and

increases with increase in feed rate.
 At low speed, higher surface roughness is obtained compared
to higher spindle speed.
 At low feed rate the thrust force is less due to less plastic
deformation.
OPTIMIZATION OF PROCESS PARAMETERS IN TURNING OF ALUMINIUM HYBRID
COMPOSITE BY TAGUCHI METHOD
LITERATURE SURVEY

AUTHORS S. Suresh Kumar et al.(2018)

MATERIAL COMPOSITION Al (6351)5 wt.% SiC and Al (6351)5 wt.% B4C-5 wt.% SiC
composite
MANUFACTURING The sample is prepared by stir casting technique
METHOD
PROPERTIES STUDIED current (I), duty factor (t), pulse on time (Ton), the gap voltage
(V) and Heat Affected Zone (HAZ)
EXPERIMENTATION The experiment is performed by varying current (I), duty factor
(t), pulse on time (Ton), and the gap voltage (V) in order to
analyze the Heat Affected Zone (HAZ) formed in the sub surface
and the average crater diameter formed on the machined
surface
EQUIPMENTS USED EDM machine, Scanning Electron Microscope(SEM)

CONCLUSION  The AlSiCB4C composite produces greater HAZ depth in the

sub surface, compared to AlSiC composite.
 The existence of B4C particulates in the matrix produces
larger crater diameter on the machined area compared to
AlSiC composite.
 MULTI RESPONSE OPTIMIZATION OF PROCESS PARAMETERS IN TURNING OF
ALUMINIUM HYBRID COMPOSITE
LITERATURE SURVEY

AUTHORS U. A. Dabade et al.(2015)

MATERIAL Al/SiC 10% composites of two different particle size of Silicon
COMPOSITION carbide reinforcement i.e. coarse and fine (220 and 600 mesh
size).
MANUFACTURING It involves producing a melt of selected matrix material followed by
METHOD the introduction of reinforcement material through stir casting
technique.
PROPERTIES STUDIED Feed, depth of cut and preheating temperature.

EXPERIMENTATION MMCs of SiC reinforcement of two mesh size i.e. 220 and 600 are
(Al/SiC/10p/220, Al/SiC/10p/600) subjected to turning operation by
varying feed, depth of cut and preheating temperatures.
EQUIPMENTS USED Optical and Scanning Electron Microscope (SEM), MTAB CNC
turning centre.
CONCLUSION  Lower cutting forces are observed at 80°C and 100°C
temperature during machining of Al/SiC.
 Better values of surface roughness are obtained at 60°C
temperature during machining of Al/SiC.
OPTIMIZATION OF PROCESS PARAMETERS IN TURNING OF ALUMINIUM HYBRID
COMPOSITE BY TAGUCHI METHOD
LITERATURE SURVEY

AUTHORS Uppada Rama Kanth et al.(2018)

MATERIAL Fly ash and SiC in different weight percentages varying from 0 -10
COMPOSITION wt percentage with a particle size of 53 um were prepared.
MANUFACTURING The Al-Zn/fly ash/SiC reinforced composites are fabricated through
METHOD vortex method using stir casting technique.
PROPERTIES STUDIED Hardness, ultimate tensile and yield strength.

EXPERIMENTATION Al-Zn alloy reinforced with fly ash and silicon carbide was loaded in
muffle furnace and heated to above its liquidus temperature at
inert atmosphere.
EQUIPMENTS USED Muffle furnace, Scanning Electron Microscope (SEM), X-ray
Diffractometer
CONCLUSION  Voids and discontinuities are not seen in the matrix as well as
composites.
 The oxygen peaks and other contaminations were not identified
due to the utilization of inert gas during the castings.
 SiC and fly ash reinforcements increases the tensile and
ultimate yield strength.
 MULTI RESPONSE OPTIMIZATION OF PROCESS PARAMETERS IN TURNING OF
ALUMINIUM HYBRID COMPOSITE
LITERATURE SURVEY

AUTHORS A. M. Usman et al.(2014)

MATERIAL Al-7%Si alloy - Bagasse Ash (BA) having high silica and alumina
COMPOSITION contents of up to 77.29% and 10.95% respectively.
MANUFACTURING The mixture is heated in a furnace at an elevated temperature
METHOD about 700oC till the required substance is achieved.
PROPERTIES STUDIED Density, Ultimate tensile strength, Young modulus, impact strength
and hardness.
EXPERIMENTATION Tensile test, Impact test, Hardness test

EQUIPMENTS USED Metallurgical furnace, Mosanto Tensometer, Scanning Electron

Microscope (SEM), Indentic Rockwell hardness testing machine,
Hounsfield Balanced Impact Strength Testing Machine.
CONCLUSION  Addition of bagasse ash in aluminium alloy to form a composite
generally improves its mechanical properties like ultimate tensile
strength, young modulus, impact strength and hardness.
 Incorporating bagasse ash in the aluminium alloy reduces its
density to a minimum value of 2292.208kgm-3 at 30vol%.
 MULTI RESPONSE OPTIMIZATION OF PROCESS PARAMETERS IN TURNING OF
ALUMINIUM HYBRID COMPOSITE
LITERATURE SURVEY

AUTHORS C.Saravanan et al.(2015)

MATERIAL Aluminium alloys
COMPOSITION
MANUFACTURING Solid state process and Liquid state process.
METHOD
PROPERTIES STUDIED Density, mechanical properties, corrosion wear resistance and
thermal coefficient of expansion
EXPERIMENTATION Stir casting, squeeze casting, spray deposition, friction stir casting,
liquid metal infiltration, vapour deposition techniques.
CONCLUSION  Among all the fabrication techniques considered, stir casting
stands out as the most economical method.
 Mechanical alloying of powder result in improvement in
hardness, compressive strength and indirect tensile strength.
 MULTI RESPONSE OPTIMIZATION OF PROCESS PARAMETERS IN TURNING OF
ALUMINIUM HYBRID COMPOSITE
LITERATURE SURVEY

AUTHORS D.Srinivas et al.(2016)

MATERIAL Al 1100-B4C
COMPOSITION
MANUFACTURING This mixture is manufactured by two step stir casting technique.
METHOD
PROPERTIES STUDIED Cutting speed, feed and surface roughness

EXPERIMENTATION The parameters are optimized by Taguchi approach

EQUIPMENTS USED Banka lathe machine, Lathe tool dynamometer and Surftest SJ201

CONCLUSION  Empirical multiple linear regression equations are developed to

predict the response variables, surface roughness, cutting
forces Fx and Fz respectively.
 With respect to cutting force Fz, weight percentage has the
maximum influence (63.17%) followed by speed (24.42%), feed
(6.28%) and DOC (0.006%).
 MULTI RESPONSE OPTIMIZATION OF PROCESS PARAMETERS IN TURNING OF
ALUMINIUM HYBRID COMPOSITE
LITERATURE SURVEY

AUTHORS Diptikanta Das et al.(2017)

MATERIAL Al 7075/SiC
COMPOSITION
MANUFACTURING This mixture is manufactured by stir casting technique.
METHOD
PROPERTIES STUDIED spindle speed, feed and depth of cut

EXPERIMENTATION The parameters are optimized by ANOVA technique.

EQUIPMENTS USED Jay Crucible make electrical resistance furnace

CONCLUSION  Surface roughness reduces with increase in lathe spindle

speed, but increases with increase in either feed or depth of cut.
 Results of ANOVA revealed that feed was the most significant
parameter followed by spindle speed and the influence of depth
of cut was significant for surface roughness.
 MULTI RESPONSE OPTIMIZATION OF PROCESS PARAMETERS IN TURNING OF
ALUMINIUM HYBRID COMPOSITE
LITERATURE SURVEY

AUTHORS A.Saravanakumar et al.(2017)

MATERIAL Al 6063 with carbon nitride inserts
COMPOSITION
MANUFACTURING This mixture is manufactured by stir casting technique.
METHOD
PROPERTIES STUDIED cutting speed, feed, depth of cut, surface finish and roundness

EXPERIMENTATION The parameters are optimized by Taguchi approach.

EQUIPMENTS USED CNC Turning Centre Model Sprint 16TC, Roughness tester

CONCLUSION  Minimum surface roughness is obtained at optimum level

Spindle speed 1200 rpm, feed 0.15 mm/rev and depth of cut
0.5mm.
 Increases in speed reduces the surface roughness and increase
in feed increases the surface roughness.
 Surface roughness and roundness error are minimum at
optimum level which generates turned parts with good surface
finish.
MULTI RESPONSE OPTIMIZATION OF PROCESS PARAMETERS IN TURNING OF
ALUMINIUM HYBRID COMPOSITE
METHODOLOGY
LITERATURE SURVEY

SELECTION OF MATERIALS

MANUFACTURING PROCESS

SAMPLE PREPARATION

MACHINING OPERATIONS

MICROSTRUCTURAL ANALYSIS

RESULTS AND DISCUSSION

 MULTI RESPONSE OPTIMIZATION OF PROCESS PARAMETERS IN TURNING OF
ALUMINIUM HYBRID COMPOSITE
REFERENCES
 Thorough Literature survey has been carried out to identify the selection of
machining parameters for desired surface roughness and minimizing the tool
cast for machining Al hybrid composite.
 Using TAGUCHI METHOD , the statistical significance and the percentage of
contribution of the machining parameters are to be evaluated.
 MULTI RESPONSE OPTIMIZATION OF PROCESS PARAMETERS IN TURNING OF
ALUMINIUM HYBRID COMPOSITE
REFERENCES
1. C.G.Sozhamannan et al., ”Machining Characteristics Of Al /Ticp/Gr Hybrid
Composites”(2017)
2. V.M.Ravindaranth et al., “Optimization of Al/B4C and Al/B4C/Gr MMC Drilling
Using Taguchi Approach”(2016)
3. S. Suresh Kumar et al., “Investigating the surface integrity of aluminium based
composites machined by EDM”(2018)
4. U. A. Dabade et al., “Experimental study of surface integrity of Al/SiC particulate
metal–matrix”(2015)
5. Uppada Rama Kanth et al., “Mechanical behaviour of fly ash/SiC particles
reinforced Al-Zn alloy-based metal matrix composites fabricated by stir casting
method”(2018)
 MULTI RESPONSE OPTIMIZATION OF PROCESS PARAMETERS IN TURNING OF
ALUMINIUM HYBRID COMPOSITE
REFERENCES
6. A. M. Usman et al., “Production and Characterisation of Aluminium Alloy -
Bagasse Ash Composites”(2014)
7. A. Włodarczyk-Fligier et al., “Fabrication of aluminium metal matrix composite –a
review”(2015)
8. D.Srinivas et al., “Optimization of Machinability Parameters of Al1100-B4C
Composites using Taguchi Method”(2016)
9. Diptikanta Das et al., ” Optimization of machining parameters and development
of surface roughness models during turning Al-based metal matrix composite
”(2017)
10. A.Saravanakumar et al., “Optimization of CNC Turning Parameters on
Aluminum Alloy 6063 using TaguchiRobust Design”(2017)
11.Siva Kumar B ET Al., "Study of Wear and Microstructural behavior of Hybrid
Aluminium Metal Matrix Composite manufactured by using Stir casting
Technique"(2017).
TIMIZATION OF PROCESS PARAMETERS IN ALUMINIUM HYBRID
COMPOSITE BY TAGUCHI METHOD
THANK YOU