Enhancing machining efficiency in hybrid metal matrix composites through EDM parameter optimization via grey relational analysis

Abstract

In summary, this study utilized stir casting to develop three distinct aluminum hybrid composites incorporating boron carbide and alumina. These composites were identified as Al7075 + 12%B4C + 6%Al2O3, Al7075 + 6%B4C + 6%Al2O3, and Al7075 + 6 %B4C + 12%Al2O3. The research focused on machining these composite materials using EDM and employed a Taguchi L27 orthogonal array design to plan the machining tests. Key process parameters considered were gap voltage (V), duty cycle (%), current (A), and different percentages of reinforcement content. The study applied Grey Relational Analysis to evaluate the impact of EDM machining process parameters on critical output responses, specifically material removal rate ( MRR ) and tool wear rate ( TWR ).