Development of forecast models on electrical discharge machined graphene nanoplatelets reinforced aluminum composite fabricated via stir casting route

Abstract

High specific strength and good fatigue limit are the key properties to watch out during development of aerospace components. Aluminum composites are proven high specific strength materials especially graphene embedded composites worth a mention in this context. While, surface finish is an eminent parameter affecting fatigue strength of a component showcasing the importance of machining technique employed to transform a fabricated bulk into finished product. Current study, therefore emphasizes on electrical discharge machining (EDM) of aluminum composites embedded with graphene nanoplatelets (1.5 wt.%) fabricated through a hybrid approach of blending solid and liquid metallurgical routes. Further, mathematical and neurological forecast models are developed to individually predict the machining response variables namely surface roughness (SR), material removal rate (MRR) and tool wear rate (TWR). Among machining parameters current (I), pulse on-time (T_on), pulse off-time (T_off) and flushing pressure (P) considered; T_on is noted to greatly influence the surface quality of composite while TWR and MRR are affected by current during ANOVA analysis. On comparative understanding of forecast models, neurological models outperform quadratic non-linear mathematical models where accuracy of prediction achieved by developed artificial neural network (ANN) model is 96% for surface roughness. The error performance plots, error histograms and overall fit plots depict a marginal over-fit neurological model. However, significantly high coefficient of correlation (R) of 99% possessed by ANN model illustrates their potential in forecasting response parameters.

Keywords:

• Aluminum nanocomposite
• artificial neural networks
• electrical discharge machining
• graphene nanoplatelets
• material removal rate
• surface roughness

Reviewing Editor:

• Swadesh Kumar Singh, Gokaraju Rangaraju Institute of Engineering and Technology, India

SUBJECTS:

• Manufacturing Engineering
• Mechanical Engineering
• Production Engineering
• Composites

Author contributions

Tarun Kumar Kotteda performed the experiments, collected the data, and wrote the original draft; Manoj Kumar defined the methodology and worked on the software; Pramod Kumar supervised the work; Ajay Gupta reviewed and edited the manuscript; all authors read and approved the final manuscript.

Disclosure statement

No potential conflict of interest was reported by the author(s).

Data availability statement

Data sharing is not applicable to this article, as no datasets were generated or analyzed during the current study.

Additional information

Funding

No funding was received.

Notes on contributors

Tarun Kumar Kotteda

Kotteda Tarun Kumar is a Research Scholar in the Department of Mechanical engineering at Dr B. R. Ambedkar National Institute of Technology, Jalandhar, India. He received his M.Tech. degree in Thermal Engineering from Jawaharlal Nehru Technological University, Kakinada, Andhra Pradesh, India. His areas of interest are Characterization of materials, Composites, Unconventional machining, Optimization and Alternative fuels. He had published 15 research papers in various International Journals and conferences to his credit. He had received gold medal from National Design Research Forum, Bangalore in the year 2018 for best project design in Mechanical Engineering Stream.

Manoj Kumar

Dr. Manoj Kumar is an Assistant Professor in the Department of Mechanical Engineering at Dr B. R. Ambedkar National Institute of Technology, Jalandhar, India. He received his M.Tech. degree in Design Engineering from Motilal Nehru National Institute of Technology, Allahabad. He obtained his Ph.D. degree from I.I.T Kanpur. His areas of interest are Solid Mechanics, Ductile Fracture: Continuum Damage Mechanics Model, Dynamic Fracture Mechanics, High Strain Rate Behavior, Large Deformation Elasto-Plastic Impact/Contact Problems, Finite Element Method and Computer-Aided Design. He had published more than 30 research papers in various International/National Journals and conferences.

Pramod Kumar

Dr. Pramod Kumar received his M.Tech. degree in Computer Integrated Design and Manufacturing from National Institute of Technology, Jamshedpur. He obtained his Ph.D. degree in Mechanical Engineering from Dr B. R. Ambedkar National Institute of Technology, Jalandhar, India. His areas of interest are Renewable Energy and Composite Materials. Currently he is serving as Professor in the Department of Mechanical Engineering at Dr B. R. Ambedkar National Institute of Technology, Jalandhar, India. He had published more than 40 research papers in various International/National Journals and conferences.

Ajay Gupta

Dr. Ajay Gupta received his M.Tech. and Ph.D. degree in Industrial Engineering from Dr B. R. Ambedkar National Institute of Technology, Jalandhar, India. His areas of interest are Operations Management, Materials Management and Lean Manufacturing. Currently he is serving as Associate Professor in the Department of Industrial and Production Engineering at Dr B. R. Ambedkar National Institute of Technology, Jalandhar, India. He had published more than 25 research papers in various International/National Journals and conferences.