Wear and Frictional Behaviour of Al 7075/FA/SiC Hybrid MMC’s Using Response Surface Methodology

Silicon ◽  
2021 ◽  
Author(s):  
Ravi Kumar Mandava ◽  
Vajrala Venkata Reddy ◽  
Veeravalli Rama Koteswara Rao ◽  
K. Srinivasulu Reddy
2021 ◽  
Vol 3 (7) ◽  
Author(s):  
Murahari Kolli ◽  
A. V. S Ram Prasad ◽  
Dasari Sai Naresh

Abstract Abstract The present study deals with the machining of hybrid Al 7075/B4C/Gr composite using Abrasive Aqua Jet Machining. The effects of selected input factors, i.e., water jet pressure (WJP), stand-off distance (SOD), and traverse speed (TS) on the performance characteristics, namely taper angle (TA), surface roughness (Ra), and the material removal rate (MRR) are investigated. The experimental runs and test strategies are formulated using the Response Surface Methodology-Central Composite Design approach. Analysis of Variance (ANOVA) was used to examine the effect of input factors and their interactions with performance characteristics. MRR, Ra, and TA optimum condition and mathematical equations were also developed. Further, the multi-optimization method “Technique for Order of Preference by Similarity to Ideal Solution” is considered to find out the best combinations of input factors for optimized output factors on the hybrid composite. The ANOVA results confirm that among the input factors, WJP and SOD are the most significant factors, and the percentage distribution of input factors are found to be jet pressure (55.21%), stand-off distance (23.36%), and traverse speed (2.56%). The multi-objective optimum conditions of the input factors are WJP (A1) 210 bar, SOD (B1), and TS (C3) 30 mm/min, that produce optimal values of the considered responses, i.e., MRR up to 4.8703 mm3/min, Ra up to 3.57 μm and TA up to 0.189°. The TA has improved by 49.6% through the multi-objective optimum results when compared with single parameter optimized results. Article Highlights Hybrid Al7075/B4C/Gr composite fabricated through the rotary stir casting technique Experimental planning and designing layouts using Response Surface Methodology scheme and mathematical equations are produced with Design Expert 11.0. The best TA was obtained by RSM-TOPSIS approach, found at a lower WJP and SOD and a higher TS.


Materials ◽  
2021 ◽  
Vol 14 (16) ◽  
pp. 4703
Author(s):  
Mohammad Azad Alam ◽  
Hamdan H. Ya ◽  
Mohammad Yusuf ◽  
Ramaneish Sivraj ◽  
Othman B. Mamat ◽  
...  

The tenacious thirst for fuel-saving and desirable physical and mechanical properties of the materials have compelled researchers to focus on a new generation of aluminum hybrid composites for automotive and aircraft applications. This work investigates the microhardness behavior and microstructural characterization of aluminum alloy (Al 7075)-titanium carbide (TiC)-graphite (Gr) hybrid composites. The hybrid composites were prepared via the powder metallurgy technique with the amounts of TiC (0, 3, 5, and 7 wt.%), reinforced to Al 7075 + 1 wt.% Gr. The microstructural characteristics were investigated by optical microscopy, scanning electron microscopy (SEM), X-ray diffraction (XRD) and energy dispersive X-ray spectroscopy (EDS) elemental mapping. A Box Behnken design (BBD) response surface methodology (RSM) approach was utilized for modeling and optimization of density and microhardness independent parameters and to develop an empirical model of density and microhardness in terms of process variables. Effects of independent parameters on the responses have been evaluated by analysis of variance (ANOVA). The density and microhardness of the Al 7075-TiC-Gr hybrid composites are found to be increased by increasing the weight percentage of TiC particles. The optimal conditions for obtaining the highest density and microhardness are estimated to be 6.79 wt.% TiC at temperature 626.13 °C and compaction pressure of 300 Mpa.


2021 ◽  
Author(s):  
Ravi Kumar Mandava ◽  
Vajram Venkata Reddy ◽  
Veeravalli Rama Koteswara Rao

Abstract In the present research work an effort has been made to study the wear and frictional behavior of Aluminium Metal Matrix composite (Al 7075 as a base alloy and fly ash (FA) and silicon carbide (SiC) as reinforcements) by using the stir casting method. To carry out this work, the wt. % of reinforcements FA (2.5%, 5%, 7.5% and 10%) and SiC (2.5%, 5%, 7.5% and 10%)have been used 5%, 10%, 15% and 20%. Initially, the mechanical studies have been conducted and the best mechanical properties obtained at 20 wt. % of FA and SiC. Later on, the composite was fabricated by 20 wt. % of FA, SiC reinforcements are used to check the wear and frictional behavior on a pin-on-disc machine at the dry condition. The dry sliding wear behavior was carried out at various input parameters such as applied force (10N, 20N, and 30N), sliding velocity (1.5m/s, 3m/s, and 4.5m/s), and sliding distance (1000 m, 2000 m, and 3000 m). Further, a scanning electron microscope (SEM) are used to observe the mixing of reinforcements and examine the worn surfaces. A response surface methodology (RSM) is the reasonable and accurate method for conducting the experiments and identifying the optimal wear parameters. Moreover, the RSM was helped to identify the most significant factor, which was the influence on the wear rate. Finally, it is decided that the applying force is the utmost significant factor that leaves an effect on wear rate. The sliding velocity and distance are acting as the lesser influence on the performance indicator.


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