Optimization of Machining Parameters in ECM of Al/B4C Composites Using Taguchi Method

Aluminium metal matrix composites (AMMCs) are now gaining their usage in aerospace and automotive industries because of their inherent properties like high strength to weight ratio, low wear rate etc. Electrochemical Machining (ECM) allowed success in the production of newer materials, especially for the aerospace and biomedical applications. In this paper an attempt is made to machine the LM6 Al/B4Cp composites using electrochemical machining process. Boron carbide particles of 30 micron size are reinforced in LM6 Al alloy matrix with 2.5%, 5% and 7.5% by weight. Taguchi’s L27 orthogonal array is chosen to design the experiments and 27 tests are conducted to study the effect of various machining parameters like applied voltage, feed rate, electrolyte concentration and percentage of reinforcement on the material removal rate (MRR), surface roughness (SR) and radial over cut (ROC). Signal-to-noise (S/N), the analysis of variance (ANOVA) and regression analyses are employed to find the optimal levels and to analyze the effect of electrochemical machining parameters on MRR, SR and ROC. Confirmation tests with optimal levels of machining parameters are conducted to validate the test results. Experimental results have shown that the responses in ECM can be improved effectively through this approach.