Hybrid design

Electrical discharge diamond face surface grinding (EDDFSG) is a hybrid machining technique consisting of face surface electrical discharge grinding and diamond face surface grinding. The machining of hybrid metal matrix composites (HMMCs) is still facing challenges for better machining performance. In the present article, an effort was made for hybrid design-based experimental modelling, performance prediction and multi-objective optimization of EDDFSG of Al/Al2O3p/B4Cp and Al/SiCp/B4Cp HMMCs. Gap current, on-time, off-time, abrasive grit number, revolutions per minute (RPM) of wheel and table speed are the process parameters whose effects on material removal rate and surface roughness (Ra) were analysed. The machining characteristics of HMMCs were investigated using performance predictions. Binary coded modified distance-based Pareto genetic algorithm was integrated with hybrid design-based RSM models for multi-objective optimization of EDDFSG process. The surface texture and re-solidified layers were also analysed using scanning electron microscopy. The selected optimized results were found to have better material removal rate and surface finish along with negligible presence of re-solidified layers during verification experiments