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3rd International Conference on Advances in Mechanical Engineering (ICAME 2020) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 912 (2020) 032016 doi:10.1088/1757-899X/912/3/032016

Optimization of Process Parameters using Taguchi Technique

for Drilling Aluminium Matrix Composites (LM6 / B4C)

C Sarala Rubi, J Udaya Prakash and C Rajkumar

Department of Mechanical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D
Institute of Science and Technology, Chennai, India.

E-mail: [email protected]

Abstract. Due to their abrasive behaviour, metal matrix composites (MMCs) are difficult to
machine, so it is necessary to develop a suitable technology for their efficient machining. The
ultimate goal of the research is to study the impact of process variables such as reinforcement,
drill type, speed and feed rate on the thrust force and burr height during AMCs drilling.
Aluminium Matrix Composites were manufactured with LM6 aluminium alloy as matrix and
B4C as reinforcement through the low cost stir casting process. Experiments were performed
using L27 orthogonal array in a CNC Vertical Machining Centre equipped with cutting tool
dynamometer to measure the thrust force and burr-height was measured using vision
measuring system. Experimental results demonstrated that this strategy enhances the
performance characteristics expected in the drilling phase.

1. Introduction
A composite is a material composed of components manufactured by a physical mixture of pre-
existing ingredients to obtain a new material with specific characteristics compared to the material's
monolithic properties [1]. A composite is a material system that is closely bound to a few specific
constituents. The reinforcement may be whiskers, particulates, plates, rods, etc. The matrix can be
made of carbon, plastic, ceramic or organic material.A composite's constituents do not entirely
dissolve or merge into each other, but act in concert. With enormous combinations, this yields infinite
possibilities, making it an ' evergreen ' field of study [2]. Aluminium composites have substantially
improved properties, including high tensile strength, toughness stiffness, low density and strong
resistance to wear compared to alloys or other metals. There has been a huge interest in low-density
and low-cost composites [3]. Aluminium bonded with silicon carbides are cheaper composite, offering
greater strength and rigidity with negligible density improvement over the base alloy. Silicon Carbide
are usually harder compared to the matrix of aluminium. The addition of SiC to the aluminium matrix
makes machining more complex than traditional materials [4]. Ultra-hard abrasive reinforcement
induces excessive wear of tools which causes major problem during the processing of such MMCs [5,
6]. Moreover, drilling MMCs is a complex task for industrial purposebecause of the weak machining
features of MMCs. Unlike traditional materials machining, several issues arise during MMC drilling,
such as wear of equipment, heavy drilling forces, and burr. Around 75% of the components require
some holes, so drilling is unavoidable [7, 8]. A bush is developed around the hole to strengthen it and
the feature of the hole is equal to that of traditional drilling. It is also referred as flow drilling [9]. The
reinforcement of carbides in the aluminium matrices leads to improve wear resistance and strength
which makes them suitable for elevated temperature applications [10].

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3rd International Conference on Advances in Mechanical Engineering (ICAME 2020) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 912 (2020) 032016 doi:10.1088/1757-899X/912/3/032016

Design of Experiment (DOE) is a very good tool for modelling. DOE method using Taguchi
method is made to optimize processes and to define the maximum combination of factors for a given
approach [11, 12]. Taguchi designs offer a good method of designing products that perform in a
variety of conditions continually and efficiently. Taguchi technique produces a typical orthogonal
array that takes into account the impact of multiple factors on the target value and determines the
experiment plan. Experiments are designed to examine the parameters impacting the response [13]. A
standardized S / N ratio is used in this approach to calculate the current variation. Such Signal to Noise
ratios are proposed to be used as representations of the cause on performance features of noise factors.
Analysis of Variance is used to evaluate the response to the design parameters. It is a computational
technique which quantitatively evaluates and represents as a percentage contribution to the overall
response [14, 15].

2. Experimental Procedure

2.1. Materials Used

Aluminium alloy LM6 is a matrix material and boron carbide (B4C) is the reinforcement in this
analysis. Materials were carefully chosen depends upon characteristics, price, applications etc.
Aluminium alloy (LM6) is difficult to process, first of all because of its ability to drag and secondly
due to the extreme rapid wear of the tool caused by increased content of silicon. Under normal
atmospheric and marine environments, aluminium alloy (LM6) reveals good corrosion resistance. It
can be cast into thin and hard parts, compared to all other casting alloys. Table 1 reveals the chemical
composition of aluminium alloy (LM6).

Table 1.Elemental Composition of Aluminium Alloy (LM6).

Constituent Silicon Copper Iron Magnesium Manganese Titanium Nickel Zinc Aluminium
Weight 11.48% 0.013% 0.52% 0.02% 0.01% 0.02% 0.01% 0.01% Remainder

Average size of 63 microns of Boron Carbide (B4C) were used as one of the element for
reinforcement. It has severalproperties, like high hardness and absorption of neutrons, which
contribute infabricating Boron Carbide widely used as soldier materials. For nuclear applications,
boron carbide is unique. Figure 1 reveals the morphology of B4C particles.

Figure 1. Morphology of Boron Carbide.

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3rd International Conference on Advances in Mechanical Engineering (ICAME 2020) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 912 (2020) 032016 doi:10.1088/1757-899X/912/3/032016

2.2. Fabrication of Aluminium Matrix Composites (LM6/B4C)

Stir casting technique has been used to produce aluminium matrix composites (LM6/B4C). Figure 2
demonstrates stir casting system with furnace.In a graphite crucible, the ingots of Aluminium Alloy
LM6 are taken and heated in the electrical furnace. The Thermal energy is increased from lower
temperature to 850°C. A solid dry hexachloro ethane (C2Cl6, 1 percent wt) degassed the melt at 800°C.
Then, molten aluminium is agitated and the boron carbide particles preheated (250°C) are added.
At 600 rpm, the slurry was stirred for 10 minutes. The melted metal is added to the potassium
hexaflurotitanate (K2TiF6, 1% wt). The purpose of introducing titanium to Boron Carbide composite
casting is to create an interface reaction layer containing TiC and TiB2 to develop bonding. Potassium
and Fluoride contribute to eliminate the oxide film on the aluminium surface with the adding of
Titanium (Ti) as K2TiF6. The boron carbide is added in the proportion of three, six and nine eight
percentage. The dispersed stirred molten aluminium is transferred into cast iron moulds preheated at
650°C and lowered to ambient environment. The dimension of the composite plates are 100 x 100 x 10
mm.

Figure 2.Fabrication of Aluminium Alloy LM6 by Stir Casting Setup.

2.3. Drilling of AMCs

The drilling of aluminium metal matrix composites is an important manufacturing process. The
experiments have been carried out with required cutting situations in the Vertical MachiningCenter.
The data acquisition device controlled by the computer is used to obtain and store the experiment
data.Kistler dynamometer is used to compute the thrust force.

Figure 3. Vertical Machining Centre (VMC 100).

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3rd International Conference on Advances in Mechanical Engineering (ICAME 2020) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 912 (2020) 032016 doi:10.1088/1757-899X/912/3/032016

2.4. Design of Experiments

Taguchi technique, a powerful tool for developing performance characteristics, has been used in this
work. L27 orthogonal array has been selected which has the capacity to control interactions between
variables. Table 2 displays the levels of each parameter for drilling experiments.

Table 2. Drilling Parameters – Levels.

Level
Process Parameters Level 2 Level 3
1
Feed rate (F)
50 100 150
mm/min
Spindle speed (S)
1000 2000 3000
rpm
TiN
Drill material (D) HSS Carbide
Coated
Reinforcement (R) % 3 6 9

2.5. Drilling Tool Materials

Three different cutting tool materials are used, which are HSS, Carbide and TiN coated carbide. The
drill diameter is 6 mm, point angle is 118o and helix angle is 30o for all the three drills. The
photograph of drills used in this research work is shown in figure 4.

Figure 4. Photograph of Drills.

3. Results and discussions

The set chosen was the 27-row (L27). The experimental strategy comprised of 27 runs using the first,
second, fifth and eight columns for feed, speed, drilling material and reinforcement percentage
respectively.Table 3 shows the experimental results.

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3rd International Conference on Advances in Mechanical Engineering (ICAME 2020) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 912 (2020) 032016 doi:10.1088/1757-899X/912/3/032016

Table 3. Experimental Results.

Thrust Burr
Expt Feed Speed Drill Reinforcement S/N S/N
Force height
No. (mm/min) (rpm) Material % Ratio Ratio
(N) (µm)
1. 50 1000 HSS 3 144.4 -43.191 0.113 18.938
2. 50 1000 Carbide 6 147.8 -43.393 0.096 20.355
3. 50 1000 Coated 9 223.9 -47.001 0.121 18.344
4. 50 2000 HSS 6 197.5 -45.911 0.024 32.276
5. 50 2000 Carbide 9 233 -47.347 0.228 12.854
6. 50 2000 Coated 3 78.27 -37.872 0.226 12.905
7. 50 3000 HSS 9 145.5 -43.257 0.131 17.655
8. 50 3000 Carbide 3 143.1 -43.113 0.109 19.251
9. 50 3000 Coated 6 169 -44.558 0.417 7.604
10. 100 1000 HSS 3 236.2 -47.466 0.351 9.094
11. 100 1000 Carbide 6 225.4 -47.059 0.288 10.802
12. 100 1000 Coated 9 304 -49.657 0.036 28.955
13. 100 2000 HSS 6 249.9 -47.955 0.068 23.307
14. 100 2000 Carbide 9 247.6 -47.875 0.170 15.374
15. 100 2000 Coated 3 159.4 -44.050 0.184 14.704
16. 100 3000 HSS 9 200.4 -46.038 0.119 18.489
17. 100 3000 Carbide 3 215.9 -46.685 0.176 15.073
18. 100 3000 Coated 6 224.7 -47.032 0.077 22.233
19. 150 1000 HSS 3 318.3 -50.057 0.390 8.179
20. 150 1000 Carbide 6 252.9 -48.059 0.705 3.040
21. 150 1000 Coated 9 517.7 -54.282 0.268 11.437
22. 150 2000 HSS 6 288.9 -49.215 0.045 27.000
23. 150 2000 Carbide 9 250.8 -47.987 0.209 13.583
24. 150 2000 Coated 3 228.7 -47.185 0.564 4.969
25. 150 3000 HSS 9 242.4 -47.691 0.577 4.776
26. 150 3000 Carbide 3 229.4 -47.212 0.176 15.073
27. 150 3000 Coated 6 185.4 -45.362 0.297 10.535

3.1. S/N Ratios - Taguchi Method

Taguchi method uses orthogonal arrays to minimize the uncertainty and to maximise the process
characteristics. The S/N ratio is employed in Taguchi approach as a performance criterion for finding
process reliability and calculating variance from optimal values. Larger values of S / N ratios are
needed to decrease the noise and the influence of unmanageable variables. Higher the value of Signal
to noise ratio, better is the quality. Figure 5 shows that the thrust force decreases with decrease in feed
rate and increase in spindle speed. It is also inferred that the thrust force decreases with the decrease in
reinforcement percentage of the material and increase in hardness of the drill material. The obtained
results are in good agreement with earlier researches.

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3rd International Conference on Advances in Mechanical Engineering (ICAME 2020) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 912 (2020) 032016 doi:10.1088/1757-899X/912/3/032016

Figure 5. Response Graphs for Thrust Force.

3.2. Response Table for Thrust Force
Table 4 shows the average response feature for each variable. Rank was allotted for highest variable to
the least variable, probably based on the response characteristics, depending on delta value in the
response table. More delta value is given first rank. From table 4, it can be concluded that feed rate
and reinforcement percentage are the most influential process parameters for obtaining minimum
thrust force. This is because of the phenomena that lower feed rate and less reinforcement percentage
leads to less thrust force on the work piece material.

Table 4. Response Table for Thrust Force.

Level Feed Speed Drill Reinforcement
1 -43.96 -47.8 -46.75 -45.2
2 -47.09 -46.16 -46.53 -46.51
3 -48.56 -45.66 -46.33 -47.9
Delta 4.6 2.14 0.42 2.7
Rank 1 3 4 2

3.3. Analysis of Variance (ANOVA)

Table 5 reveals the ANOVA for Thrust Force. Feed has contributed 42 % in determining thrust force,
followed by speed, drill and reinforcement. The F-value from table at 5% significance level is F0.05,
2, 6 = 5.14. So, from ANOVA Table 5 we see that feed rate is the significant parameter for thrust
force.

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3rd International Conference on Advances in Mechanical Engineering (ICAME 2020) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 912 (2020) 032016 doi:10.1088/1757-899X/912/3/032016

Table 5. ANOVA Table for Thrust Force.

Contribution
Source DF SS MS F P
%
Feed 2 99.376 49.688 6.08 0.036 42.698
Speed 2 22.49 11.245 1.38 0.322 9.663
Drill 2 0.797 0.398 0.05 0.953 0.342
Reinforcement 2 32.831 16.415 2.01 0.215 14.106
Feed*Speed 4 8.579 2.145 0.26 0.892 3.686
Feed*Drill 4 5.669 1.417 0.17 0.944 2.436
Feed*Reinforcement 4 13.988 3.497 0.43 0.784 6.010
Residual Error 6 49.012 8.169 21.059
Total 26 232.741 100.000

3.4. S/N Ratios - Taguchi Method

Taguchi used orthogonal arrays to reduce uncertainty and the method features are maximized. The S/N
ratio is used as a quality criterion in Taguchi approach to finding process accuracy and to determine
variance from optimum values. Larger Signal to noise ratio values are required to reduce the noise and
impact of uncontrollable parameters. Figure 6 shows that the burr height decreases with decrease in
feed rate and increase in spindle speed. It is also inferred that the burr height decreases with the
increase in reinforcement percentage of the material and decrease in hardness of the drill material.

Figure 6. Response Graphs for Burr Height.

3.5. Response Table for Burr Height

The mean response feature for each variable is shown in Table 6. Rank has been assigned to the
highest variable to the least variable, mainly based on the response features, depending on the
response table delta value. First rank is given with more delta value. From table 4, it can be concluded

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3rd International Conference on Advances in Mechanical Engineering (ICAME 2020) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 912 (2020) 032016 doi:10.1088/1757-899X/912/3/032016

that feed rate and reinforcement percentage are the most influential process parameters for obtaining
minimum burr height. This is because of the phenomena that lower feed rate and less reinforcement
percentage leads to less burr height on the work piece material.

Table 6. Response Table for Burr Height.

Drill
Level Feed Speed Reinforcement
type
1 17.8 14.35 17.75 13.13
2 17.56 17.44 13.93 17.46
3 10.95 14.52 14.63 15.72
Delta 6.84 3.09 3.81 4.33
Rank 1 4 3 2

3.6. Analysis of Variance (ANOVA)

Table 7 reveals the ANOVA for Burr height. Feed has contributed 19.5 % in determining thrust force,
followed by speed, drill and reinforcement. The F-value from table at 5% significance level is F0.05,
2, 6 = 5.14. So, from ANOVA Table 5 we see that no factor has significance on thrust force.

Table 7. ANOVA Table for Burr Height.

Adj Contribution
Source DF Seq SS F P
MS %
Feed 2 271.5 135.75 1.5 0.296 19.507
Speed 2 54.36 27.18 0.3 0.751 3.906
Drill type 2 74.15 37.08 0.41 0.681 5.328
Reinforcement 2 85.42 42.71 0.47 0.645 6.137
Feed*Speed 4 83.87 20.97 0.23 0.911 6.026
Feed*Drill type 4 208.15 52.04 0.57 0.692 14.956
Feed*Reinforcement 4 71.25 17.81 0.2 0.931 5.119
Residual Error 6 543.1 90.52 39.022
Total 26 1391.79 100.000

3.7. Confirmation Experiments

Experimental results were analyzed to find out the optimum drilling conditions. Optimum features for
getting minimum thrust force are feed rate of 50 mm/min, spindle speed of 3000 rpm, Titanium
Nitride Coated drill material and 3% of reinforcement. The predicted thrust force is 138 N and the
experimental thrust force is 143.1 N. So the optimization satisfies the research work. Optimum
features for getting minimum burr height are feed rate of 50 mm/min, spindle speed of 2000 rpm, HSS
drill material and 6% of reinforcement. The predicted value of burr height is 0.102 µm and the
experimental burr height value is 0.024 µm. From the experimental results of burr height, we can see
that only 6 values are less than the predicted value, so the optimization satisfies the research work.
4. Conclusions
The following conclusions were drawn by analyzing the impact of drilling process parameters of
aluminum matrix composites.
i) Aluminium matrix composites (LM6/B4C) 3%, 6% and 9% were successfully produced through stir
casting technique.

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3rd International Conference on Advances in Mechanical Engineering (ICAME 2020) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 912 (2020) 032016 doi:10.1088/1757-899X/912/3/032016

ii) Feed (42.698 %) has the highest statistical influence on Thrust Force followed by reinforcement
(14.106%) and Speed (9.663%).
iii) Feed (19.507%) has the highest statistical influence on Burr Height followed by interaction
between drill material and feed.
iv) Confirmation experiments show that there is a marginal error associated with the responses.

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