Turning Process Characteristics of Aluminium Matrix Hybrid Composite Using Grey Relational Surface Methodology

Aluminium metal matrix composites have generated huge attention in modern industries because of its high strength-to-weight ratio, low density and corrosion resistance. Turning is a widely used material removal process to produce cylindrical products. Presence of solid lubricant reinforcements such as graphite (Gr), carbon nanotube (CNT) and hexagonal boron nitride (hBN) could increase the feasibility of turning on aluminium metal matrix composites. Aluminium alloy 6061 reinforced with B₄C (5–15 vol.%) and hBN (10 vol.%) particulates were fabricated using stir casting process. The effect of process parameters such as feed, speed, depth of cut and volume percentage of boron carbide has been investigated to explore the impact on tangential force, cutting power and tool wear. Experiments were conducted using Taguchi’s L₂₇ orthogonal array (OA). The factors affecting the responses were optimized by applying grey-response surface methodology (G-RSM) using grey relational grade (GRG) calculated by normalized S/N ratio and grey relational coefficient (GRC).