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<p>This study details about the one of the electro chemical machining (ECM) characteristics i.e material removal rate (MRR) for hybrid composite Al8011/B<sub>4</sub>C/fly-ash. The hybrid composite was prepared by keeping fly-ash proportion constant as 2 %. The boron carbide (B<sub>4</sub>C) reinforcement is varied as 3 %, 8 % and 13 %. The MRR is calculated by conducting ECM of the hybrid composite. The important testing parameters considered in this study are voltage (V), concentration of electrolyte (in g/litre) and duty cycle (in %). Thirty six experiments were conducted for predicting the MRR in relation to the ECM parameters. The study clearly revealed that the voltage has direct correlation with MRR and influenced the MRR more. The other parameters such as electrolyte concentration and duty cycle also affected the MRR values slightly. The contour plots and residual plots were plotted from that the significance of MRR in relation to the machining parameters can be understood. The study showed a variation of 70.67 % between the minimum and maximum experimental MRR values, as observed from the conducted ECM experiments. <i>The confirmation test conducted at the optimal machining conditions resulted in a prediction error of 2.90 %, indicating good agreement between experimental and predicted values</i>.</p>

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Machining performance optimization of Al8011/B4C/fly ash hybrid composite in electrochemical process

  • 期刊论文

  • 发表日期：

    2026年7月11日

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  • N. S. Nandakumar,
  • M. Sambathkumar,
  • K. S. K. Sasikumar,
  • R. Gukendran

摘要

This study details about the one of the electro chemical machining (ECM) characteristics i.e material removal rate (MRR) for hybrid composite Al8011/B4C/fly-ash. The hybrid composite was prepared by keeping fly-ash proportion constant as 2 %. The boron carbide (B4C) reinforcement is varied as 3 %, 8 % and 13 %. The MRR is calculated by conducting ECM of the hybrid composite. The important testing parameters considered in this study are voltage (V), concentration of electrolyte (in g/litre) and duty cycle (in %). Thirty six experiments were conducted for predicting the MRR in relation to the ECM parameters. The study clearly revealed that the voltage has direct correlation with MRR and influenced the MRR more. The other parameters such as electrolyte concentration and duty cycle also affected the MRR values slightly. The contour plots and residual plots were plotted from that the significance of MRR in relation to the machining parameters can be understood. The study showed a variation of 70.67 % between the minimum and maximum experimental MRR values, as observed from the conducted ECM experiments. The confirmation test conducted at the optimal machining conditions resulted in a prediction error of 2.90 %, indicating good agreement between experimental and predicted values.