Experimental Investigation of Surface Integrity and Multi-Objective Optimization of End Milling for Hybrid Al7075 Matrix
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ORIGINAL PAPER
Experimental Investigation of Surface Integrity and Multi-Objective Optimization of End Milling for Hybrid Al7075 Matrix Composites Suha K. Shihab 1
&
Jabbar Gattmah 1 & Hala M. Kadhim 1
Received: 8 February 2020 / Accepted: 13 May 2020 # Springer Nature B.V. 2020
Abstract Cost effective machining of hybrid metal matrix composites (HMMC’s) with required surface integrity and without surface flaws is a challenging task for modern industries. This research explores the effect of end milling factors (spindle speed, feed rate, and depth of cut) and also weight percentage of reinforced materials on the surface integrity (surface roughness and microhardness) and material removal rate during machining of hybrid Al7075/SiC/Gr composites. Response surface methodology (RSM) is selected for experimental design and experimental results are analyzed using analysis of variance (ANOVA). Further, multiobjective optimization is carried out using composite desirability function. In addition, the morphology of the milled surfaces is examined for defining the flaws that affect quality of the milled surfaces. The experimental results reveal that apart from spindle speed and feed rate, the weight percentage of reinforced materials significantly affects the surface integrity of hybrid Al7075/SiC/ Gr composites. The obtained optimum levels of the factors are spindle speed at 1000 rpm, feed rate at 0.0677 mm/rev, depth of cut at 1.1869 mm, and weight percentage of reinforced materials at 12.6970% that produce optimal values of the considered responses i.e. material removal rate up to 2043 mm3/min, roughness up to 1.29 μm and microhardness up to 142.36 μH. Keywords Surface integrity . Hybrid Al7075/SiC/Gr composites . RSM design . Multi objective optimization, . Milling process
1 Introduction Benefits such as high specific strength, weight reduction and development of functional properties has made metal matrix composites (MMC’s) very popular. Aluminum matrix based MMC’s possess tremendous properties such as lighter weight, superior fatigue, wear and corrosion resistance, high strength, and low density and therefore, Aluminum matrix composites are being widely used in lieu of the conventional Aluminum alloys. Aluminum matrix composites are broadly employed in aerospace, marine, automobile, and military for the manufacturing of an extensive range of components. The requirement to enhance the strength of aluminum for aeronautic applications and other industrial sectors has prompted the investigation on effect of stiffer and stronger reinforcement components * Suha K. Shihab [email protected]; [email protected] 1
Department of Materials Engineering, College of Engineering, University of Diyala, Diyala, Iraq
such as oxides, carbides and nitrides to the aluminum matrix. The choice of suitable strengthening particles enhances the mechanical properties, maximizes the efficiency, broadens the application in modern requirements of Aluminum alloy [1–3]. The particles such as SiC, ZrO2, B4C, Al2O3, TiC,
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