Optimization of process variables in drilling of LM6/fly ash composites using Grey-Taguchi method

Drilling is a critical step in the hole-making operation. It is quite beneficial for part assembly. Hard particulates introduced into the continuous phase of the composite materials, makes them hard to process. As a result, optimizing the drilling variables is inevitable . The primary goal of this study is to manufacture LM6/Fly Ash with weight percentages of fly ash 3, 6 and 9 adopting the stir casting technique. The second objective is to use Taguchi's Design of Experiments (L-27 OA) to drill composite materials using feed rate (F), spindle speed (S), drill material (D), and % of reinforcement (R) as drilling process variables at 3 levels. The ultimate goal is to optimize the drilling process variables for obtaining minimum thrust force (TF), surface roughness (SR) and burr height (BH) using multi-objective Grey Relational Analysis. The optimum process variable achieved is F1S3D3R3, i.e., 50 mm/min, 3000 rpm, TiN-coated drill bit and 9 wt% of fly ash. Copyright (C) 2022 Elsevier Ltd. All rights reserved.