Performance Optimization of Electrochemical Machining Parameters on Aluminum Metal Matrix Composite

Abstract

The aluminum metal matrix composite (AMMC) is now occupying an irreplaceable space in various industries due its advantages such as a great strength to the weight ratio, good wear resistance, and a reduced density. In this paper, the AMMC was developed using aluminum 7075 reinforced with 5 and 10% boron carbide. The L₁₈ orthogonal array was used for conducting the electrochemical micromachining experiments. The AMMC was a wire cut into thin sheets; and specimen 1 designates the AMMC with 5% boron carbide, and specimen 2 designates the AMMC with 10% boron carbide. The tool electrode was of a diameter of 0.5 mm, and sodium nitrate was used as an electrolyte. The technique for order of preference by similarity to ideal solution and the principal component analysis were utilised in order to find out the best parameter combination on the machining speed, the diametral overcut, and the delamination factor. The electrolyte concentration of 35 g/L, the voltage of 11 V, and the duty cycle of 70% were found to be the optimal combination for the machining speed, the diametral overcut, and the delamination factor in specimen 1. The ANOVA analysis results showed that the duty cycle is a significant factor, with its 53.5% contribution.