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Machinability analysis and optimisation of EDM in AA6082/3 wt% BN/1 wt% MoS2 hybrid composites using entropy method weights integrated with complex proportional assessment (COPRAS) method

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Abstract

An investigation was made on composites containing AA6082 as matrix and boron nitride/molybdenum disulphide (BN/MoS2) as reinforcement, which was a composite materials hybrid at 3 wt% of BN and 1% MoS2 and fabricated by stir casting methodology. Using electrical discharge machining (EDM) equipment, machinability studies were undertaken to achieve an optimal condition on process parameters. Taguchi (L27 orthogonal array)-based design of experiments was employed to examine the influence of process parameters like pulse on time (Ton), peak current (IP), and gap voltage (V) on material removal rate (MRR), circularity (CIRC), electrode wear rate (EWR), and cylindricity (CYLD). Multi-criteria decision-making (MCDM) methodology was employed for the process parameters while machining AA6082/3 wt% BN/1% MoS2 hybrid composites. An entropy-based objective weights method was integrated with the complex proportional assessment (COPRAS) approach to assess the most excellent optimal level of process parameters. The entropy (Wj) weights were 0.1285, 0.1002, 0.5707, and 0.2005 for MRR, EWR, CIRC, and CYLD. Optimal conditions are obtained from the COPRAS method of relative significance score, and quantitative utility assessment score in the nineteenth experiment having the 15 A, 50 μs, and 30 V with the relative significance score of 0.0735 and a higher quantitative utility score of 100% being achieved. Using an SEM, the machined surface is analysed for the micro-structural examination. At higher peak current (IP), micro-voids and craters with poor surface finish were located.

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Funding

This work is supported by the Fundamental Research Funds of Shandong University (2019HW040) and Future for Young Scholars of Shandong University, China (31360082064026).

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Authors and Affiliations

  1. Department of Mechanical Engineering, Sri Vidya College of Engineering and Technology, Virudhunagar, Tamil Nadu, India

    Karthik Pandiyan Ganesan

  2. Department of Mechanical Engineering, K. Ramakrishnan College of Engineering, Trichy, Tamil Nadu, India

    Jafrey Daniel James Dhilip, Arjun Duraipalam, Gowtham Seenivasan, Gokul Kannan Perumal & Bhuvaneshwar Karthikeyan

  3. Key Laboratory of High-Efficiency and Clean Mechanical Manufacture, National Demonstration Center for Experimental Mechanical Engineering Education, School of Mechanical Engineering, Shandong University, Jinan, 250061, Shandong, China

    Vinothkumar Sivalingam

  4. Department of Mechanical Engineering, K. Ramakrishnan College of Technology, Trichy, Tamil Nadu, India

    Ram Kumar Rajagopal

  5. Department of Mechanical Engineering, M. Kumarasamy College of Engineering, Karur, Tamil Nadu, India

    Mohanraj Chandran

Authors
  1. Karthik Pandiyan Ganesan
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  2. Jafrey Daniel James Dhilip
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  3. Vinothkumar Sivalingam
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  4. Arjun Duraipalam
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  6. Gokul Kannan Perumal
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  7. Bhuvaneshwar Karthikeyan
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Contributions

Karthik Pandiyan Ganesan: conceptualisation, experimental work and data curation, and writing—review and editing; Jafrey Daniel James Dhilip: data curation and writing—review and editing; Vinothkumar Sivalingam: supervision, funding and data curation writing—review and editing, and technical validation; Arjun Duraipalam: experimental work; Gowtham Seenivasan: experimental work; Gokul Kannan Perumal: experimental work; Bhuvaneshwar Karthikeyan: experimental work; Ram Kumar Rajagopal: experimental work; Mohanraj Chandran: experimental work and technical validation.

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Correspondence to Jafrey Daniel James Dhilip or Vinothkumar Sivalingam.

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Ganesan, K.P., Dhilip, J.D.J., Sivalingam, V. et al. Machinability analysis and optimisation of EDM in AA6082/3 wt% BN/1 wt% MoS2 hybrid composites using entropy method weights integrated with complex proportional assessment (COPRAS) method. Int J Adv Manuf Technol 123, 4051–4064 (2022). https://doi.org/10.1007/s00170-022-10462-2

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