TAGUCHI-GREY OPTIMIZATION OF SURFACE ROUGHNESS AND MATERIAL REMOVAL RATE ON ELECTRO-DISCHARGE MACHINING OF NOVEL AA7075-TiO2 METAL MATRIX COMPOSITE USING WASTE CORNCOB BIOSILICA DIELECTRICS

D. Sakthimurugan, L. Antony Michael Raj, V. Antony Aroul Raj and K. Thavasilingam
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D. Sakthimurugan: Department of Mechanical Engineering, Easwari Engineering College, Chennai, India
L. Antony Michael Raj: ��Department of Mechanical Engineering, Loyola-ICAM College of Engineering, Chennai, India
V. Antony Aroul Raj: Department of Mechanical Engineering, Easwari Engineering College, Chennai, India
K. Thavasilingam: Department of Mechanical Engineering, Easwari Engineering College, Chennai, India

Surface Review and Letters (SRL), 2025, vol. 32, issue 1, 1-10

Abstract: In this study, a novel AA7075-TiO2 metal matrix composite was machined utilizing a biosilica mixed EDM technique and the surface roughness and material removal rate are optimized. The biosilica particles are produced from waste maize cobs and then silane-treated. The optimization of process variables wasperformed using Taguchi grey relational approach with a process variable of peak current, gap voltage and pulse-on time. Results revealed that the gap voltage is the most important process variable, since it has a larger max-min difference of 0.25. In order to create a high MRR of 11.6mm3/min and a surface roughness of 2.25 m, the maximum GRG of 0.79 for Trial 1 (A2B1C3) represents the most ideal process variable group. The best results appear to be obtained with a peak current of 10 A, a gap voltage of 20V, and a pulse-on time of 140μs. The new GRG, however, is around 2.51% better than the anticipated optimized process variables of A2B1C3 with an old GRG of 0.79, according to the confirmation research. The new MRR of 11.89mm3/min and the surface roughness of 2.30s with a GRG of 0.81 are based on the optimized new process variables (A1B1C3).

Keywords: Powder EDM, MMC, filler, gap voltage; peak current, pulse time (search for similar items in EconPapers)
Date: 2025
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DOI: 10.1142/S0218625X24501038

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