Multi-Response Optimization of Milling Process Parameters for Aluminium-Titanium Diboride Metal Matrix Composite Machining Using Taguchi- Data Envelopment Analysis Ranking Approach

Giridhar B. Kamath,1

Krishnan Subramaniam,2

Sonal Devesh,3

Vijaykumar Chavan,4

Nanjangud Mohan,5

Ritesh Bhat5*Email

Heshan Thenuka Wijerathne 6

1Department of Humanities & Management, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal 576104 India.

2Department of Mechanical Engineering, School of Engineering and Computing, Manipal International University, Nilai, Malaysia 71800

3Post Graduate Studies and Research, College of Banking and Financial Studies, Muscat, Sultanate of Oman.

4Department of Mechanical Engineering, Smt. Kamala and Sri Venkappa M. Agadi College of Engineering & Technology, Lakshmeshwar, Gadag. 582116 India.

5Department of Mechanical and Manufacturing Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal 576104 India.

6Schoool of Civil and Mechanical Engineering, Curtin University, Bentley, Western Australia 6102 Australia.

Abstract

Ceramic reinforced aluminum matrix composites are increasingly gaining importance because of their specific physical features, particulate reinforced. Machining such materials is a time-consuming process due to their superior physical properties. Moreover, only a few recorded research documents discuss the optimization of machining parameters in the milling of Aluminium-Titanium Diboride (Al/TiB2) composites. Thus, the current study sought to evaluate the effect of process parameters on the face milling machining process while machining Al/TiB2 metal matrix composite. Reinforcement weight percentage, cutting speed, feed rate, and depth of cut used in milling were used as input parameters in the Taguchi-DEA ranking methodology to evaluate performance metrics, including material removal rate and material's arithmetic average roughness. According to the results of the experimental investigation, cutting speed and reinforcement weight percentage have a greater influence on determining performance metrics in the milling process due to their role in determining impact strength. Among the selected process factors, the ideal combination of reinforcing weight percent (9%), cutting speed (1500 rpm), feed rate (300 mm/min), and depth of cut (0.15) were discovered and evaluated using a confirmation test with 3.14 and 2.34 percent variation in material removal rate (MRR) and surface roughness (Ra) values, respectively.

Multi-Response Optimization of Milling Process Parameters for Aluminium-Titanium Diboride Metal Matrix Composite Machining Using Taguchi- Data Envelopment Analysis Ranking Approach