Parametric Optimization of Powder-Mixed EDM of AA2014/Si<sub>3</sub>N<sub>4</sub>/Mg/Cenosphere Hybrid Composites Using Fuzzy Logic: Analysis of Mechanical, Machining, Microstructural, and Morphological Characterizations
This research focuses on a comprehensive exploration of the experimental and mechanical aspects of the electrical discharge machining (EDM) process, specifically targeting the machining characteristics of AA2014/Si<sub>3</sub>N<sub>4</sub>/Mg/cenosphere hybrid composites. The...
| Main Authors: | , , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2023-09-01
|
| Series: | Journal of Composites Science |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2504-477X/7/9/380 |
| _version_ | 1797579473715986432 |
|---|---|
| author | G. Rajkumar M. Saravanan A. Bovas Herbert Bejaxhin Shubham Sharma Shashi Prakash Dwivedi Rajeev Kumar Sunpreet Singh |
| author_facet | G. Rajkumar M. Saravanan A. Bovas Herbert Bejaxhin Shubham Sharma Shashi Prakash Dwivedi Rajeev Kumar Sunpreet Singh |
| author_sort | G. Rajkumar |
| collection | DOAJ |
| description | This research focuses on a comprehensive exploration of the experimental and mechanical aspects of the electrical discharge machining (EDM) process, specifically targeting the machining characteristics of AA2014/Si<sub>3</sub>N<sub>4</sub>/Mg/cenosphere hybrid composites. The aim is to optimize the process parameters for enhanced machining performance through a combination of testing, optimization, and modelling methodologies. The study examines the effects of key EDM variables—peak current, pulse on time, and pulse off time—on critical output responses: surface roughness (Ra), electrode wear rate (EWR), and material removal rate (MRR). Leveraging an L9 Taguchi orthogonal array experimental design, the impact of controllable factors on these responses is analysed. An integrated approach utilizing MATLAB’s logic toolbox and Mamdani’s technique is employed to model the EDM process, and a multiple-response performance index is calculated using fuzzy logic theory, enabling multiobjective optimizations. Furthermore, a mechanical behaviour evaluation of AA2014/Si<sub>3</sub>N<sub>4</sub>/Mg/cenosphere hybrid composites is performed through mechanical testing, with a comparison between experimental machining results and predicted values. Scanning electron microscopy (SEM) images reveal the presence of filler reinforcements within the base alloy, displaying an improved microstructure and uniform reinforcement dispersion. An X-ray diffraction (XRD) analysis confirms the major elemental constituents—aluminium, silicon, and magnesium—in the hybrid composites. A microstructural analysis of the hybrid metal matrix composites (MMCs) prepared for EDM showcases closely packed reinforcement structures, circular ash-coloured spots indicating silicon and nitrates, and a fine dispersion of cenosphere reinforcement particles. The study’s outcomes demonstrate a promising application potential for these hybrid composites in various fields. |
| first_indexed | 2024-03-10T22:36:40Z |
| format | Article |
| id | doaj.art-e2f856a7b98441e9a3c3cb119617f3a0 |
| institution | Directory Open Access Journal |
| issn | 2504-477X |
| language | English |
| last_indexed | 2024-03-10T22:36:40Z |
| publishDate | 2023-09-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Composites Science |
| spelling | doaj.art-e2f856a7b98441e9a3c3cb119617f3a02023-11-19T11:22:36ZengMDPI AGJournal of Composites Science2504-477X2023-09-017938010.3390/jcs7090380Parametric Optimization of Powder-Mixed EDM of AA2014/Si<sub>3</sub>N<sub>4</sub>/Mg/Cenosphere Hybrid Composites Using Fuzzy Logic: Analysis of Mechanical, Machining, Microstructural, and Morphological CharacterizationsG. Rajkumar0M. Saravanan1A. Bovas Herbert Bejaxhin2Shubham Sharma3Shashi Prakash Dwivedi4Rajeev Kumar5Sunpreet Singh6Annai College of Engineering and Technology, Kumbakonam 612503, Tamil Nadu, IndiaPonjesly College of Engineering, Parvathipuram, Nagercoil 629003, Tamil Nadu, IndiaSaveetha School of Engineering, SIMATS, Chennai 602105, Tamil Nadu, IndiaDepartment of Mechanical Engineering, University Centre for Research and Development (UCRD), Chandigarh University, Mohali 140413, Punjab, IndiaDepartment of Mechanical Engineering, Lloyd Institute of Engineering & Technology, Knowledge Park II, Greater Noida 201306, Uttar Pradesh, IndiaSchool of Mechanical Engineering, Lovely Professional University, Phagwara 144411, Punjab, IndiaDepartment of Mechanical Engineering, University Centre for Research and Development (UCRD), Chandigarh University, Mohali 140413, Punjab, IndiaThis research focuses on a comprehensive exploration of the experimental and mechanical aspects of the electrical discharge machining (EDM) process, specifically targeting the machining characteristics of AA2014/Si<sub>3</sub>N<sub>4</sub>/Mg/cenosphere hybrid composites. The aim is to optimize the process parameters for enhanced machining performance through a combination of testing, optimization, and modelling methodologies. The study examines the effects of key EDM variables—peak current, pulse on time, and pulse off time—on critical output responses: surface roughness (Ra), electrode wear rate (EWR), and material removal rate (MRR). Leveraging an L9 Taguchi orthogonal array experimental design, the impact of controllable factors on these responses is analysed. An integrated approach utilizing MATLAB’s logic toolbox and Mamdani’s technique is employed to model the EDM process, and a multiple-response performance index is calculated using fuzzy logic theory, enabling multiobjective optimizations. Furthermore, a mechanical behaviour evaluation of AA2014/Si<sub>3</sub>N<sub>4</sub>/Mg/cenosphere hybrid composites is performed through mechanical testing, with a comparison between experimental machining results and predicted values. Scanning electron microscopy (SEM) images reveal the presence of filler reinforcements within the base alloy, displaying an improved microstructure and uniform reinforcement dispersion. An X-ray diffraction (XRD) analysis confirms the major elemental constituents—aluminium, silicon, and magnesium—in the hybrid composites. A microstructural analysis of the hybrid metal matrix composites (MMCs) prepared for EDM showcases closely packed reinforcement structures, circular ash-coloured spots indicating silicon and nitrates, and a fine dispersion of cenosphere reinforcement particles. The study’s outcomes demonstrate a promising application potential for these hybrid composites in various fields.https://www.mdpi.com/2504-477X/7/9/380EDMAl hybrid compositestestingDoEgrey analysisMATLAB |
| spellingShingle | G. Rajkumar M. Saravanan A. Bovas Herbert Bejaxhin Shubham Sharma Shashi Prakash Dwivedi Rajeev Kumar Sunpreet Singh Parametric Optimization of Powder-Mixed EDM of AA2014/Si<sub>3</sub>N<sub>4</sub>/Mg/Cenosphere Hybrid Composites Using Fuzzy Logic: Analysis of Mechanical, Machining, Microstructural, and Morphological Characterizations Journal of Composites Science EDM Al hybrid composites testing DoE grey analysis MATLAB |
| title | Parametric Optimization of Powder-Mixed EDM of AA2014/Si<sub>3</sub>N<sub>4</sub>/Mg/Cenosphere Hybrid Composites Using Fuzzy Logic: Analysis of Mechanical, Machining, Microstructural, and Morphological Characterizations |
| title_full | Parametric Optimization of Powder-Mixed EDM of AA2014/Si<sub>3</sub>N<sub>4</sub>/Mg/Cenosphere Hybrid Composites Using Fuzzy Logic: Analysis of Mechanical, Machining, Microstructural, and Morphological Characterizations |
| title_fullStr | Parametric Optimization of Powder-Mixed EDM of AA2014/Si<sub>3</sub>N<sub>4</sub>/Mg/Cenosphere Hybrid Composites Using Fuzzy Logic: Analysis of Mechanical, Machining, Microstructural, and Morphological Characterizations |
| title_full_unstemmed | Parametric Optimization of Powder-Mixed EDM of AA2014/Si<sub>3</sub>N<sub>4</sub>/Mg/Cenosphere Hybrid Composites Using Fuzzy Logic: Analysis of Mechanical, Machining, Microstructural, and Morphological Characterizations |
| title_short | Parametric Optimization of Powder-Mixed EDM of AA2014/Si<sub>3</sub>N<sub>4</sub>/Mg/Cenosphere Hybrid Composites Using Fuzzy Logic: Analysis of Mechanical, Machining, Microstructural, and Morphological Characterizations |
| title_sort | parametric optimization of powder mixed edm of aa2014 si sub 3 sub n sub 4 sub mg cenosphere hybrid composites using fuzzy logic analysis of mechanical machining microstructural and morphological characterizations |
| topic | EDM Al hybrid composites testing DoE grey analysis MATLAB |
| url | https://www.mdpi.com/2504-477X/7/9/380 |
| work_keys_str_mv | AT grajkumar parametricoptimizationofpowdermixededmofaa2014sisub3subnsub4submgcenospherehybridcompositesusingfuzzylogicanalysisofmechanicalmachiningmicrostructuralandmorphologicalcharacterizations AT msaravanan parametricoptimizationofpowdermixededmofaa2014sisub3subnsub4submgcenospherehybridcompositesusingfuzzylogicanalysisofmechanicalmachiningmicrostructuralandmorphologicalcharacterizations AT abovasherbertbejaxhin parametricoptimizationofpowdermixededmofaa2014sisub3subnsub4submgcenospherehybridcompositesusingfuzzylogicanalysisofmechanicalmachiningmicrostructuralandmorphologicalcharacterizations AT shubhamsharma parametricoptimizationofpowdermixededmofaa2014sisub3subnsub4submgcenospherehybridcompositesusingfuzzylogicanalysisofmechanicalmachiningmicrostructuralandmorphologicalcharacterizations AT shashiprakashdwivedi parametricoptimizationofpowdermixededmofaa2014sisub3subnsub4submgcenospherehybridcompositesusingfuzzylogicanalysisofmechanicalmachiningmicrostructuralandmorphologicalcharacterizations AT rajeevkumar parametricoptimizationofpowdermixededmofaa2014sisub3subnsub4submgcenospherehybridcompositesusingfuzzylogicanalysisofmechanicalmachiningmicrostructuralandmorphologicalcharacterizations AT sunpreetsingh parametricoptimizationofpowdermixededmofaa2014sisub3subnsub4submgcenospherehybridcompositesusingfuzzylogicanalysisofmechanicalmachiningmicrostructuralandmorphologicalcharacterizations |