Multi-objective optimization of high-speed end milling on Al6061/ 3% RHA/ 6% TiC reinforced hybrid composite using Taguchi coupled GRA

Advanced machining techniques have been carried out in the manufacturing sector in order to improve the quality of the product. Growing demand of materials on engineering applications tend to have composite materials in the form of addition of some reinforcements. Machining the ceramic reinforced Al-MMC‘s is a challenging task for manufactures. Aluminium hybrid composite fabricated through liquid metallurgy. Four specimens with varying reinforcement weight fractions (3%+3%, 3%+6%, 3%+9%, 3%+12%)fabricated by ultrasonic stir-casting. Among A16061/3Wt. % of RHA/6Wt. % of TiC had better mechanical properties and lightweight suitable for structural applications. The machinability of aluminium hybrid composite is evaluated by the end milling process. End milling is found to be suitable machining for surface finishing. High-speed end milling operations conducted using an 8 mm diameter WC inserts with the control parameters of Spindle Speed (SS), Feed Rate (FR)and Cutting Depth (CD). Effect on output responses such as average surface roughness (Ra)and Material Removal Rate (MRR)have been investigated. Experiments performed using the Taguchi L9 orthogonal array (OA)with low, medium and high-level parameters. The effect and percentage contribution of the governing parameters on the output response was analyzed using ANOVA. Optimum parameters for the lower Ra, i.e. SS = 1500 rpm, FR = 100 mm/min and CD = 0.2 mm result in a good surface finish. SS and CD are the most significant variables for Ra. Experiment 8th resulted in optimum parameters for lower Ra and higher MRR using GRA. A change of 25.53% was observed in the predicted conditions.