Implementation of Taguchi approach on the aluminum alloy 2219 metal matrix composites to improve the quality of the drilling process

Abstract

Aluminum alloy 2219 is commonly used in the aerospace and automobile industries due to its favorable properties of low density, high strength, and good performance at cryogenic temperatures. To improve the mechanical and thermal properties of Al 2219, three reinforcements were added in preparation for the hybrid metal matrix composite (HMMC) such as silicon carbide (SiC), molybdenum disulfide (MoS₂), and graphite (Gr). Drilling is a significant manufacturing process, and the investigation of drilling parameters indicates the quality of the drilling process in terms of tool life, hole quality, and energy consumption. In this research work, drilling parameters such as thrust force, torque, and burr were evaluated. Taguchi method is implemented to design an experiment with an L9 orthogonal array. The experiment was conducted with coated carbide and uncoated carbide drill tools. Coated carbide was used because it improves oxidation resistance and reduces friction. The specimen prepared with Al 2219 + 15%SiC + 5%Gr produced the maximum thrust force, torque, and burr when drilled with a coated carbide drill tool compared to other specimens. Feed rate was the main parameter that influenced thrust force and torque. The maximum burr height was produced by the coated carbide drill tool compared to the uncoated carbide drill tool. The metal matrix composite specimen is prepared with a novel combination of reinforcement and matrix materials such as aluminum alloy 2219, Silicon carbide (SiC), and Molybdenum disulfide (MoS₂).