Journal
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
Volume 21, Issue 4, Pages 481-491Publisher
SPRINGER
DOI: 10.1007/s11665-011-9861-z
Keywords
AMCs; APM-EDM; gray relational analysis; multiple responses; optimization; orthogonal array
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Abrasive powder-mixed electrical discharge machining (APM-EDM), a hybrid manufacturing process involving the use of a dielectric fluid mixed with abrasive powder, combines the benefits of mechanical and thermal interactions. The aim of this article is to use a new approach of performance evaluation, gray relational analysis (GRA), to evaluate the effectiveness of optimizing multiple performance characteristics of APM-EDM of 6061Al/Al2O3p/20p aluminum matrix composites (AMCs). The considered process parameter includes the seven control factors namely pulse current (A), pulse ON time (mu s), duty cycle (%), gap voltage (V), time interval of tool lift (s), abrasive powder concentration (g/L), abrasive particle size (mu m), and a noise factor, aspect ratio (shape of tool electrode). The combination of L18 (2(1) x 3(7)) orthogonal array design of experiment with GRA enables to determine the optimal parameters for multiple responses. GRA is used to obtain a single performance index, gray relational grade through gray relational coefficient to optimize the APM-EDM process with lower tool wear rate, surface roughness, and higher material removal rate. In addition, analysis of variance (ANOVA) for the GRC is also utilized.
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