Parametric Optimization and Evaluation of Machining Performance for Aluminium-Based Hybrid Composite Using Utility-Taguchi Approach

Further developments in the current generation cannot be accomplished without considering the involvement of composite materials. In recent times, these materials have become popular among engineers and being extensively used all over. As the composite materials are produced by net shape, additional processing such as machining is required for their end-user applications. Machining of composites is needed not only for assemblage but also for creating and controlling the required tolerances of the parts. All such activities consume a lot of time and money. Hence, optimization must be done before mass manufacturing of the components bringing the costs down as well as minimizing the flaws of the surface fabricated by the machining operation. In this context, an attempt has been accomplished to examine the machinability aspects of an aluminium-based hybrid metal matrix composite (MMC). The experimental design was based on Taguchi’s concept of L₉ orthogonal array where cutting speed (V), feed (f), and depth of cut (d) have been considered as machining variables with a three-level of variations. Material removal rate (MRR) and surface roughness (R_a) were the output characteristics of the operation. The application of the ANOVA technique has been applied to access the significance of each input variable to the output responses. To obtain the best parametric settings, the utility function approach in conjunction with the Taguchi method has been implemented. This novel optimization route based on the integrated concept of the Taguchi-utility approach yields the optimal parametric setting as V = 1200 RPM, f = 0.132 mm/rev., and d = 0.21 mm.