Process Parameters Optimization of Pin and Disc Wear Test to Minimize the Wear Loss of General-Purpose Aluminium Grades by Taguchi and Simulation Through Response Surface Methodology

B.S. Ravindranath,1

B.R.N. Murthy,2*Email

H.C. Ramu2 

S. Sandeep Nambiar2

1Department of Biotechnology, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal, Karnataka, 576104, India.

2*Department of Mechanical and Manufacturing Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal, Karnataka, 576104, India.

Abstract

Mechanical parts are frequently subjected to friction which generates heat at the contact zones, resulting in wear of the parts which reduces the components life and leads to the higher power consumption. Because of their exceptional characteristics, aluminium (Al) and its alloys find a wide range of applications in industry and daily life. These alloys range from the 1xxx series to the 7xxx series. However, research is continuously being performed to develop superior, low-cost, high-strength alloys that provide the best wear outcomes. In the present study, an attempt has been made to optimize the process parameters on pin and disc wear test as per American Society for Testing and Materials (ASTM) standard Grain size (G)99-05 on 2xxx series alloys – Aluminum Al 2011, Al 2014, and Al 2024. The results reflect that, the parameter disc speed has the greatest influence on the wear loss of the specimen and the material type has the least effect at 95% the confidence level. In the present work, the optimum combination of parameters determined through the Taguchi and Response Surface Methodology (RSM). It is proved from the work among the three materials (Al 2011, Al 2014, and Al 2024) considered for the analysis, the material Al 2024 exhibits the lowest wear loss.

Process Parameters Optimization of Pin and Disc Wear Test to Minimize the Wear Loss of General-Purpose Aluminium Grades by Taguchi and Simulation Through Response Surface Methodology