International Journal of Mechanical and Production

Engineering Research and Development (IJMPERD)

ISSN(P): 2249-6890; ISSN(E): 2249-8001
Vol. 8, Issue 4, Aug 2018, 1013-1026
© TJPRC Pvt. Ltd.

FABRICATION OF AL/FLY ASH MMC, IDENTIFYING MECHANICAL

PROPERTIES & MULTI OBJECTIVE OPTIMIZATION

FOR TURNING PROCESS USING GREY

RELATIONAL ANALYSIS

V. AJAY1, G. GURUMAHESH2, MANU RAVURI3

& T. VISHNUVARDHAN4
1,2
Assistant Professor, Department of Mechanical Engineering, SV College of Engineering,
Tirupathi, Andhra Pradesh, India
3
Associate Professor & Head, Department of Mechanical Engineering, WISE College, Tadepalligudem,
Andhra Pradesh, India
4
Professor & Dean, Department of Mechanical Engineering, CMR Institute of Technology, Hyderabad,
Telangana, India

Original Article
ABSTRACT

This paper investigates the effects and multi objective of optimization of turning process parameters. The
process parameters selected for optimization are speed, feed and depth of cut. In this study Al-LM 25 has been selected
as the base material which is having a wide variety of application in the cylinder block liners, vehicle drive shafts,
bicycle frames automotive pistons etc. An attempt had been made to increase in strength by adding 12% of Fly-ash and
8% of Magnesium to make a metal matrix composite by Steer Casting process the hardness had been increased from
66.04 BHN to 78.14 BHN. The experimental runs are carried out based on L9 Orthogonal Array (OA). Surface
Roughness (Ra) and Material Removal Rate (MRR) are taken as process responses. The objective of optimization is to
achieve minimum surface roughness and high material removal rate simultaneously, process parameters are optimized
based on Taguchi technique coupled with grey relational analysis. Analysis Of Variance (ANOVA) has been carried out
to get the contribution of each process parameters on the process responses and final effects of process parameters on
material removal rate and surface roughness is plotted and studied.

KEYWORDS: Al-LM25, Surface Roughness, Material Removal Rate, Grey Relational Analysis & MINITAB

Received: May 29, 2018; Accepted: Jul 16, 2018; Published: Aug 10, 2018; Paper Id.: IJMPERDAUG2018105

Nomenclature

OA - Orthogonal Array

Ra - Surface Roughness

MRR - Material Removal Rate

ANOVA - Analysis Of Variance

Xi(Z) - Grey relational generation value

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1014 V. Ajay, G. Gurumahesh, Manu Ravuri
& T. Vishnuvardhan

i - Grey relational grade

1. INTRODUCTION

In the earliest metal shaping techniques, casting is one of the process which is known to human being. It means
pouring molten metal into a refractory mould cavity and allows it to solidify. The solidified object is taken out of the
mould either by breaking or taking the mould part. The solidified object is called casting, and the technique followed by
the method is known as casting process.

Turning is the ejection of metal from the outer estimation of a rotating barrel moulded work piece. Its key
structure, can be described as the machining of an external surface.

Due to a low weight and low cost Al based LM25 particle reinforced metal matrix composite material is mostly
used in the engineering materials. These finds many applications like cylinder block liners, vehicle drive shafts, bicycle
frames automotive pistons etc.

1.1. Objective of Present Work

The main objective of the work is to develop a metal matrix composite of Al LM25-reinforced with fly-ash and to
study the effect of particulate material effect with respect to hardness and turning parameters like depth of cut, cutting
speed, feed rate of material removal rate and surface roughness. The above objective has been achieved by following steps.

• To prepare the Al LM25-reinforced Al composite by steer casting

• To characterize the composite material and find the hardness

• To identify ranges of process parameters for the turning of the above materials

• To perform the turning experiments and find out surface roughness, material removal rate.

• By using grey relational analysis, which is coupled with Taguchi method

• ANOVA is also performed to get the percentage contribution of each parameter on the process responses.

2. LITERATURE REVIEW

Previously, some researchers have been trying to optimize process parameters during machining. Kilickap et al.[1-
2] developed a relationship between tool wear and surface roughness to cutting parameters for machining of homogenized
sic-p reinforced aluminium metal matrix composite. The study emphasize on investigated the tool wear rate of different
coated and uncoated tool and surface roughness in different cutting parameters. It was observed that increase in
reinforcement element addition produced better mechanical properties such as impact toughness but tensile strength shoes
different trends Er-Gallab and sklad [3] focused the effect of various cutting parameters on surface quality and extend of
the sub-surface damage due to machining using PCD tools.

Puneet Bansal and Lokesh Upadhyay [4-5] Resulted that the uncoated tool is less compared to coated tool. Here
the feed rate is very low to the cutting speed on weariness of the tool bit, but, the rate of giving feed is proportional to the
tool wear. The machinability property of these composite materials is different when compared to the traditional materials,
due to the abrasive reinforcement element and having of the abrasive nature of alumina effects more wear on cutting tool.
It has been observed that the increase in reinforcement ratio effects surface roughness inversely. J. Palladium [6] found in

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Multi Objective Optimization for Turning Process Using Grey
Relational Analysis
this study influence of machining conditions. Machining parameters, the contact time of the cutting tool while turning
particulate metal matrix composites.

G. B. Veeresh kumar et al. [7] Investigated the influence of reinforcement on mechanical properties when
different metal matrix materials that is Al6061 and Al 7075 and reinforcements such as SiC and Al2O3 are used and they
observed micro hardness of the composite were increased with the increase of filler content. Venkata Prasad[8] has
investigated on factors influencing the dry sliding wear behaviour such as load, sliding speed, reinforcement content in
Al/Fly ash/Graphite hybrid metal matrix composite and the results reveals that load is the most significant parameters
influencing the wear rate of the hybrid composite followed by the sliding speed and reinforcement content. G. Elango and
B. K. Raghunath [9] resulted that, particulate reinforcement composite has high strength, hardness when compared with
matrix materials the wear resistance increase in the hybrid composite materials when the sic and TiO2 is added as
reinforcement unreinforced aluminium alloy exhibits more were followed by sic reinforced binary metal matrix composites
and then the hybrid composite composites (LM25+SiC+TiO2).

Mr. Amol D. Sable, Dr. S. D. Deshmukh [11] Studied mechanical preparation of metal- matrix composite by
stirring casting method. Satpal Kundu Dr. B. K. Roy, Ashok Kr Mishra [12] Resulted Study of Dry Sliding Wear Behavior
of Aluminium/SiC/Al2O3/Graphite Hybrid Metal Matrix Composite Using Taguchi Technique. Siddesh Kumar N G
Ravindranath V M G S Shiva Shankar [13] Investigated The hybrid composites prepared by stir casting technique for Al
2219 reinforced with hard B C & solid lubricant MoS C & solid lubricant MoS particles successfully.

Mr.Sharanabasappa R Patil, Prof B.S Motgi, Prof B.S Motgi [14] has explained that by stir casting method Al
composite material can easily prepared and the metal matrix composite microstructure shows the uniformly distributed
phases, and also explained that with the addition of Al2O3 the tensile strength and hardness of material increases. Whereas
the ductile and impact strength decreases. P. Sathiaprathap, V. S. K. Vengatachalapathy, K. Palaniradja [15] concluded that
selection of proper machining process for effective machining of hybrid Al/SiC/BC-MMC.

3. DETAILS OF THE EXPERIMENTS

3.1. Selection of the Workpiece Material

Al LM25 material having a wide variety of application in cylinder block liners, vehicle drive shafts, bicycle
frames automotive pistons automobile industry. The industries are looking for less weight, high strength materials.
Composites are the materials which can posses high strength with less weight. From the literature we selected Al LM25 as
matrix material and fly-ash, magnesium as reinforcing materials

3.2. Manufacturing of Al/Fly Ash MMC

First fly-ash is heated to 6000c to remove the impurities and water content in the fly ash, and magnesium was
99.9% pure. Al LM25 was melted in the crucible at 8500c on muffle furnace and added fly-ash and magnesium and then
they are mixed with steering machine and cast to shape of 35mm diameter and 196mm length.

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1016 V. Ajay,
Ajay G. Gurumahesh, Manu Ravuri
& T. Vishnuvardhan

Figure 3.1: Fly Ash

Figure 3.2: Stir Casting Arrangement

3.2.1. Stir Casting Method

In a stir casting process, the reinforcing phases are distributed into molten metal by mechanical stirring. The stir
casting of MMC was initiated in 1968, when S. Ray introduced alumina particles into an aluminium melt by stirring molten
aluminium alloys containing
ontaining the ceramic powders. Atypical stir casting process of MMC is illustrated in fig Mechanical
stirring in the furnace is a key element of this process by using scanning electron microscopy.
microscopy The resultant molten alloy,
with ceramic particles, can be used in sand casting. Stir casting is suitable for manufacturing composites

Figure 3.3: Crucible used for Casting

Figure 3.4: Workpiece of Composite

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Multi Objective Optimization for Turning Process Using Grey
Relational Analysis
3.2. Characterization of Workpiece Material

Table 3.1: Pure Material of Al-Lm25

Name of Al LM25 Diameter of Specimen Total Length of Specimen
Samples (gm) (mm) (mm)
S1 500 30 110
S2 400 30 90

Table 3.2: The Composition used for Metal Matrix Composite

Name of Al LM25 Magnesium Fly Ash Total Weight
Samples (gm) (gm) (gm) (gm)
S1 900 30 60 990

Table 3.3: Composition of MMC

Name of Al LM25 Magnesium Fly Ash
Samples Wt % Wt% Wt%
S2 100 8 12

3.3. Microstructures Study of Pure Material (Al-LM25)

and Composite Material (Al-Lm25/Fly Ash/Mg)

The microstructures plays an important role for analysing the distribution of distinct phases in pure aluminium
and aluminium matrix material. The microstructure was studied by using scanning electron microscope and which shows
that the phases are near uniformly distributed in the metal matrix. And the images are shown below.

Figure 3.5: Microstructure of LM25

Figure 3.6: Microstructure of Lm25 with

8% Mg and 12% fly ash

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1018 V. Ajay, G. Gurumahesh, Manu Ravuri
& T. Vishnuvardhan

4. HARDNESS TEST
4.1. Brinell Hardness Test

Hardness is defined as the resistance offered by the material to undergo mechanical deformation when load is
applied. Three methods are used to measure hardness. Out of the three Brinell hardness testing is used to measure the
resistance to the solidification behaviour when force is applied there is permanent shape change. The Macroscopic
hardness is mainly characterized with strong intermolecular bonds. For getting the accuracy of the material there are three
types of test, which are Vickers hardness test, the Rockwell hardness test and the Brinell hardness test. Out of these we
concentrated with the Brinell hardness test.

The Brinell hardness testing was performed on the sample with a load of 250Kgf and the diameter of the steel ball
indenter is 5mm. The impressions made by the steel ball were observed carefully and the diameters of the impressions
were used to calculate the hardness value of the sample.

Brinell scale is a hardness scale based on the indentation hardness of a material. The Brinell test determines the
hardness by measuring the depth of penetration of an indenter under a large load compared to the penetration made by a
preload.

The measured hardness value of the base material Al-LM25 is 66.04. The hardness of the composite
manufactured is measured and found it is increased by the value of 12.1, the measured hardness is 78.14. The increased
hardness is because fly-ash, which is a ceramic and it’s had good hardness.

5. DESIGN OF EXPERIMENTS
5.1. Taguchi Method

To get different combinations of parameters and this level for each experiment, Taguchi proposed on the
experimental plan in terms of orthogonal array. According to this technique, entire parameter space is studied with
minimum number of experiments. This approach is based on the use of orthogonal arrays to conduct small, highly
fractional factorial experiments up to larger full factorial experiment.

Table 5.1: Details of Process Parameters

A B C
Level
Speed (rpm) Feed (mm/rev) Depth of Cut (mm)
1 1000 0.025 0.5
2 1500 0.05 0.75
3 2000 0.075 1

Table 5.2: Experimentation Design

Exp A B C
1 1 1 1
2 1 2 2
3 1 3 3
4 2 1 2
5 2 2 3
6 2 3 1
7 3 1 3
8 3 2 1
9 3 3 2

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Relational Analysis
In this research there are three process parameters, namely depth of cut, speed, feed rate. The orthogonal array
chosen was L9, which has 9 rows corresponding to the number of parameter combinations.

Table 5.3: L9 Array of Process Parameter

Speed Feed DOC
Exp
(rpm) (mm/rev) (mm)
1 1000 0.025 0.5
2 1000 0.05 0.075
3 1000 0.075 1
4 1500 0.025 0.075
5 1500 0.05 1
6 1500 0.075 0.5
7 2000 0.025 1
8 2000 0.05 0.5
9 2000 0.075 0.075

5.2. Selected Response Variable

The following response variables were selected for the present work

• Surface roughness (Ra),

• Material removal rate

5.3. Turning Experiment

The 30mm diameter and 110mm, 90mm length of two specimens (pure material) and 30mm diameter, 196mm
length (MMC) work piece was subjected to turning on the lathe. After turning operation has been performed the surface
roughness and material removal rate was measured with the help of the following experiments.

5.4. Surface Roughness

The surface roughness was measured by the Mitutoyo Company Talysurf equipment shown in figure 5.1.

Figure 5.1: Talysurf Equipment

5.5. Material Removal Rate

Chang in volume of Al-fly ash material after machining are calculated

MRR=[D-d] x f x N mm3/min (1)

Where D= Before cutting diameter mm

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1020 V. Ajay, G. Gurumahesh, Manu Ravuri
& T. Vishnuvardhan

d=After cutting diameter mm

f=cutting feed rate mm/rev

N=cutting speed rpm

6. RESULTS AND DISCUSSIONS

Table 6.1: Design of Experiment and Experiment

Results for Pure Al (LM25) Material
Exp Speed Feed DOC Ra
MRR
runs (rpm) (mm/rev) (mm) (µm)
1 1000 0.025 0.5 1.22 0.545
2 1000 0.05 0.75 1.52 1.6275
3 1000 0.075 1 1.50 3.24
4 1500 0.025 0.75 1.24 1.220
5 1500 0.05 1 1.29 3.24
6 1500 0.075 0.5 1.40 2.45
7 2000 0.025 1 1.22 2.16
8 2000 0.05 0.5 1.25 2.18
9 2000 0.075 0.75 1.18 4.8825

Table 6.2: Design of experiments and

Experiment results for MMC
Exp Speed Feed DOC Ra MRR
Runs (rpm) (mm/rev) (mm) (µ) (m3/min)
1 1000 0.025 0.5 2.22 0.545
2 1000 0.05 0.75 1.611 1.6275
3 1000 0.075 1 4.42 3.24
4 1500 0.025 0.75 1.506 1.220
5 1500 0.05 1 3.389 3.24
6 1500 0.075 0.5 3.03 2.45
7 2000 0.025 1 1.215 2.16
8 2000 0.05 0.5 1.169 2.180
9 2000 0.075 075 1.348 4.8825

Material removal rate and surface roughness of Al-fly ash after machining are shown in Table 6.1. Single
responses can be optimized by Taguchi method, but machining has multiple responses, whereas Taguchi method may not
be helpful while optimizing the process parameters, grey relation analysis coupled with Taguchi method is generally used
for multiple responses.

6.1. Grey Analysis

The experimental results obtained from surface roughness and Material removal rate are presented in Table 5.3
and Table 6.1. Grey relational grade is the final response for optimizing process parameters with Taguchi analysis, which is
attained from the following set of calculations.

6.1.1. Grey Relational Generation for Pure Material and MMC Material

Grey relational generation is the first step in grey Taguchi analysis in which experimental results should be
normalized in the range of 0 to 1. For normalizing surface roughness data, lower-the-better (LB) criterion used (equation 2)
and for normalizing material removal rate data, higher-the-better (HB) criterion are used (equation 3).

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Multi Objective Optimization for Turning Process Using Grey
Relational Analysis
Xi(z) = (2)

Xi(z) = (3)

Where Xi(z) is the grey relational generation value, max Yi(z) is the greatest value of Yi(z) for zth response. Min
Yi(z) is the smallest value associated with Yi(z) for zth response. The normalized data for pure material after grey relational
generation is given table 6.2. The normalized data for MMC material after grey relational generation is given table 6.3.
Best value in normalized result is the best performance value it should be equal to 1.

Table 6.3: Normalized of Experiments

Data for Pure Material
Exp Runs Ra MRR
1 0.882 0
2 0 0.250
3 0.058 0.621
4 0.823 0.156
5 0.676 0.621
6 0.353 0.440
7 0.882 0.372
8 0.794 0.377
9 1 1

Table 6.4: Normalized of Experiments Data

for Composite Material
Exp runs Ra MRR
1 0.676 0
2 0.864 0.250
3 0 0.621
4 0.896 0.156
5 0.317 0.621
6 0.428 0.440
7 0.986 0.372
8 1 0.377
9 0.945 1

6.1.2. Grey Relational Coefficient for Pure and MMC Material

After normalizing surface roughness and MRR response data, grey relational coefficients are calculated to exhibit
relationship between the best and actual normalized experimental results. The grey relational coefficient €i(z) can be
expressed as

∆ ∆
i (z) = (4)
∆ ∆

Where, ∆0i = X0i(z)-Xi(z), ∆0i is the difference of absolute value between X0(z) and Xi(z). ∆ min is the minimum
value of ∆0i and ∆ min is the maximum value of ∆0i. φ is the identification coefficient, the value of φ in the range of 0<
φ<1, the suggested value of the distinguishing coefficient, φ is 0.5, due to moderate distinguishing effects and good
stability of outcomes. In this study, φ value is taken as 0.5 for further analysis. The grey relational coefficient values for
surface roughness and MRR are shown in table 6.3 and 6.4.

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1022 V. Ajay, G. Gurumahesh, Manu Ravuri
& T. Vishnuvardhan

Table 6.5: Grey Relational Coefficient

for Pure Material
Exp No. Ra MRR
1 0.809 0.333
2 0.333 0.40
3 0.346 0.569
4 0.738 0.372
5 0.606 0.569
6 0.436 0.472
7 0.809 0.443
8 0.708 0.445
9 1 1

Table 6.6: Grey Relational Coefficient

for MMC Material
Exp No. Ra MRR
1 0.6 0.333
2 0.786 0.40
3 0.333 0.569
4 0.828 0.372
5 0.423 0.569
6 0.466 0.472
7 0.973 0.443
8 1 0.445
9 0.91 1

6.1.3. Grey Relational Grade and Grey Relational

Ordering for Pure and MMC Material

Grey relational grade is taken as an overall process response instead of multiple response such as surface
roughness and MRR. Grey relational of grade is calculated by averaging the grey relational coefficient values of multi
responses as follows and it is indicated by Yi.

i= ∑ i z (5)

Where, n= number of responses

Higher value of grade indicates the best relational degree between the Xo(z) and Xi(z). Table 6.6 and 6.7 shows
that the grey relational grade and their orders.

Table 6.7: Grey Relational Grade & Order for Pure Material

Exp No. Grade Order

1 0.571 5
2 0.733 9
3 0.915 7
4 0.555 6
5 0.587 3
6 0.454 8
7 0.626 2
8 0.576 4
9 1 1

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Multi Objective Optimization for Turning Process Using Grey
Relational Analysis
Table 6.8: GRG & Order for
MMC Material
Exp No. Grade Order
1 0.4665 8
2 0.593 5
3 0.451 9
4 0.6 4
5 0.496 6
6 0.469 7
7 0.708 3
8 0.7225 2
9 0.955 1

6.2. Factor Effects on Grey Relational Grade for Pure and MMC Material

The main effect plot for grey relational grade is shown in figure. In the main effect plot, a parameter for which the
line has the highest inclination will have a more significant effect and the line which is near to horizontal line has no
significant effect. From the main effect plot 6 it is clear that the depth of cut (C) has a more significant effect and feed has
a less significant effect. The optimal parameter combination of pure Aluminium for minimum surface roughness and
minimum MRR are A1 B3 C2 i.e. Speed of 1000 rpm, feed of 0.075 mm/rev and depth of cut of 0.75 mm. From the main
effect plot 7 it is clear that Cutting Speed (A) has a more significant effect and feed has a less significant effect. The
optimal parameter combination of MMC for minimum surface roughness and minimum MRR are A3 B1 C1 i.e. Speed
of2000 rpm, feed of 0.025 mm/rev and depth of cut of 0.75 mm.

Main Effects Plot for gr

Data Means
s f d
0.80

0.75

0.70
Mean

0.65

0.60

0.55

0.50
1000 1500 2000 0.025 0.050 0.075 0.50 0.75 1.00

Figure 6.1: Main Effect Plot for

Mean of GR for Pure

Main Effects Plot for Gr

Data Means
s f d
0.80

0.75

0.70
Mean

0.65

0.60

0.55

0.50

1000 1500 2000 0.025 0.050 0.075 0.50 0.75 1.00

Figure 6.2: Main Effect Plot for GR for MMC

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1024 V. Ajay, G. Gurumahesh, Manu Ravuri
& T. Vishnuvardhan

6.3. Analysis of Variance

The purpose of ANOVA is to investigate which process parameter has a significant effect on the process
responses. In ANOVA values of p less than 0.050 indicates the parameter has significant effect and values more than 0.100
indicates the parameters are not significant. The percentage contribution can be calculated as:

""#
= (6)
""$

Where ssd is the sum of squared deviation for the each parameter and sst is the total sum of squared deviations. In
this study, Analysis of variance (ANOVA) has been carried out by using MINITAB 17 software. Table 6.9 shows the
Analysis of variance result in an overall grey relational grade of surface roughness and material removal rate for pure
material. Table 6.10 shows the Analysis of variance result for overall grey relational grade of surface roughness and
material removal rate for MMC material

Table 6.9: ANOVA for Grey Relational Grade for Pure Material
Source DOF Sum of Squares Mean Squares F-Ratio % Contribution
S 2 0.0840 0.0420 4.07 32.33
F 2 0.0693 0.0346 3.36 26.68
D 2 0.0858 0.0429 4.15 33.02
Error 2 0.0206 0.0103 7.95
Total 8 0.2660

Table 6.10: ANOVA for Grey Relational Grade for MMC Material
Source DOF Sum of Squares Mean Squares F-Ratio % Contribution
S 2 0.16020 0.08010 33.92 72.709
F 2 0.00172 0.00086 0.36 0.781
D 2 0.05368 0.02684 11.37 24.363
Error 2 0.00472 0.00236 2.142
Total 8 0.22033

7. CONCLUSIONS

The Al-LM25/Fly ash/Mg composite was successfully fabricated with the help of stir casting arrangement. With
proper distribution of fly ash particles all over the specimen the composite was fabricated. By adding Mg to the composite
it improves the usability of an ash particle by reducing its surface tension. The following conclusions have been drawn:

• Based on grey analysis, the optimal setting for obtaining minimum surface roughness and maximum material
removal rate for pure material are A3 B2 D3 i.e. Speed of 2000 rpm, feed of 0.05 mm/rev and depth of cut of 1
mm.

• The hardness of the material has been increased by adding fly-ash, the hardness of Al-LM25 is 66.04 and
hardness of Metal Matrix Composite is 78.14. The improved hardness is about 12.1.

• Based on grey analysis, the optimal setting for obtaining minimum surface roughness and maximum material
removal rate for Al Lm25 – Fly ash are A3 B1 C2 i.e. Speed of 2000 rpm, feed of 0.025 mm/rev and depth of cut
of 0.75 mm.

• ANOVA resulted that the cutting speed has been more influential parameter on Surface roughness and MRR for
Al LM25 – Fly ash composite.

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Improvement-A Review, International Journal of Engineering and Advanced Technology (IJEAT) ISSN: 2249 – 8958, Volume-
4. Issue-1, October 2014

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