Investigation of Tribological Performance cum Machining Efficiency with Surface Quality of Al HMMC Reinforced with ES-Gr using GRA and SEM Outcomes

The aerospace, industrial, and automotive sectors employ metal matrix composites (MMCs) because of their low mass, high strength, and structural stiffness.This study built AA6061-graphite and AA6061-graphite-eggshell hybrid composites to compare their mechanical properties to the alloy.Reinforcement pre-heating temperatures of 900 C and stir casting generated AA6061 samples reinforced with eggshell powder volumes of 0-5% and 5% graphite volumes.A pin-on disc tribometer was adjusted to assess wear.These parameters were Gr and Es weight percentage (0% to 5%), applied load (20 N to 40 N), speed (150 rpm to 450 rpm), and duration (5 to 15 minutes).The optimal wear process parameters for wear resistance are found by using response surface techniques.The results showed that alloys and composites' wear rates increased with applied load and speed.Tensile, hardness, and compression tests were utilized to assess mechanical properties, and graphite and egg shell reinforcement changed the findings.Graphite and eggshell enhance the hardness, tensile strength, and compressive strength of a substance.The results indicated that the mechanical properties of reinforced materials might be enhanced.Three significant variables determined the optimization method: feed rate (0.10 -0.15 mm/rev), spindle speed (850 -1050 rpm), and depth of cut (0.30 -0.90 mm).Responses to Metal Removal Rate, Surface Roughness, and Machining Time were investigated in the optimization study.GRA optimized Taguchi's L9 orthogonal array was utilized to execute the experimental design.The optimum cutting speed, feed rate, and depth of cut for this hybrid composite were 1050 rpm, 0.15 mm per revolution, and 0.6 mm, respectively.