Multi-Objective Optimization of Machining Parameters for Drilling LM5/ZrO2 Composites Using Grey Relational Analysis
Sunder Jebarose Juliyana1, Jayavelu Udaya Prakash1, Robert Čep2
1Department of Mechanical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, Chennai 600062, India.
Materials (Basel, Switzerland)
|May 27, 2023
Summary
This study optimized drilling parameters for LM5/Zirconium Dioxide (ZrO2) composites. Optimal settings achieved minimal thrust force, surface roughness, and burr height for enhanced material performance.
Area of Science:
- Materials Science and Engineering
- Manufacturing Processes
- Composite Materials
Background:
- Traditional engineering materials struggle to meet modern application demands, driving the use of advanced composites.
- Drilling is a critical manufacturing process, with drilled holes often acting as high-stress concentration points requiring careful consideration.
- Optimizing drilling parameters for novel composite materials is a persistent challenge for researchers and engineers.
Purpose of the Study:
- To determine optimal machining parameters for drilling LM5/Zirconium Dioxide (ZrO2) composites.
- To simultaneously minimize thrust force (TF), surface roughness (SR), and burr height (BH) in drilled holes.
- To investigate the influence of machining variables on drilling characteristics using Grey Relational Analysis (GRA).
Main Methods:
- LM5/ZrO2 composites were fabricated using stir casting with varying wt% of ZrO2 reinforcement.
- Drilling experiments were conducted using an L27 orthogonal array to explore parameter space.
- Grey Relational Analysis (GRA) was employed to identify optimal cutting parameters and assess variable significance.
Main Results:
- Optimal drilling parameters identified: 50 m/s feed rate, 3000 rpm spindle speed, Carbide drill material, and 6% ZrO2 reinforcement.
- Analysis of Variance (ANOVA) showed drill material (29.08%), feed rate (24.24%), and spindle speed (19.52%) significantly influence the grey relational grade (GRG).
- Experimental validation confirmed the predicted GRG with a minimal error of 3.7%.
Conclusions:
- The study successfully identified optimal drilling parameters for LM5/ZrO2 composites, balancing multiple performance metrics.
- Drill material, feed rate, and spindle speed are key factors influencing drilling quality in these composites.
- Developed mathematical models provide a predictive tool for optimizing drilling responses based on drill bit type.
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