Experimental investigation and optimization of machining and wear parameters of Al SiC co continuous composites

Abstract

The term co continuous refers to a class of composites in which the two phases namely metal and ceramic are topologically interconnected This results in a three dimensionally interpenetrating structure with near to isotropic properties Co continuous ceramic composites referred to as C4 possess the advantages of higher wear resistance enhanced thermal and electrical conductivity high stiffness and hardness over discontinuous phase composites In the present work three aluminium alloys namely AA2024 AA6063 and AA7068 were gravity infiltrated into porous SiC performs to manufacture co continuous composites The effect of varying machining parameters namely speed feed and depth of cut during end milling of C4 on the multi responses of surface roughness tool wear and depth of cut was investigated using Response Surface Methodology RSM Non linear regression models were generated and optimal machining parameters were determined using desirability analysis Confirmation experiments performed validated the models with a 10 error in prediction Tests have shown that by applying this technique an improvement in the response characteristics of surface roughness and tool wear has been achieved These co continuous composites also have potential in friction and braking applications due to their unique tribological characteristics Hence the present work also conducted a Taguchi Grey Relational Analysis GRA based optimization of wear parameters such as applied load sliding speed and sliding distance newline