Investigation into Machining Characteristics of Tri- Alumane Zirconium Particle Reinforcement in Metal Matrix Composite Using Ultrasonic Machining Process

Particle reinforced metal matrix composites (PRMMCs) are the materials that are extremely difficult to machine using conventional manufacturing method due to high tool wear caused by presence of the hard ceramic reinforcement. This paper presents details of an investigation into the machinability of TriAlumane zirconium (Al3Zr), Zirconia (ZrO2) and Silicon carbide (SiC)particulate reinforcedaluminium alloy matrix using nonconventional machining process such as Ultrasonic Machining (USM). The effect of different input parameters namely power rating, type of abrasive slurry, concentration of abrasive slurry, abrasive grit size and tool material were investigated on response parameters i.e. material removal rate (MRR) and Surface roughness (Ra) and significance of input parameters on variation in output responses have been analyzed by using techniques such as ANOVA. Optimization and verification of the process parameters and modelling of results has been done by applying regression analysis. Main effect plot for significant factors and S/N ratio have been used to determine the optimal design for output response. Through various experiments and comparisons with conventional results, the superiority of our novel method is verified. The paper also depicts the type of fracture that might have taken place during machining process with the help of scanning electron microscopy of machined area.