The Metal Matrix Composites (MMCs) are being used in many applications, including aerospace, shipbuilding, and defence industries owing to their high strength to weight ratio. However, the machining of these materials is still challenging, necessitating advanced machining techniques. The current investigation aimed to analyze the performance of the grinding-assisted rotary disc-electrochemical discharge machining (GA-RD-ECDM) process during cutting Al-6063 SiCp MMC. Detailed experimentation was performed to study the energy interaction behavior and effect of input process variables viz. applied voltage, pulse on time, electrolyte concentration, and disc rotation speed on performance measures. The responses selected were taper, overcut (WOC), and Materials Removal Rate (MRR). The experimentation work was performed by adopting response surface methodology. Regression models were developed and statistically analyzed through analysis of variance (ANOVA). Eventually, the GA-RD-ECDM process was optimized using the VIKOR methodology of multi-criteria decision-making by considering accuracy and productivity simultaneously to obtain minimum taper and WOC and maximum MRR. The results of ANOVA revealed that input variables were statistically significant. Applied voltage most significantly affects the performance of the GA-RD-ECDM process performance. The optimal values of input process variables obtained by VIKOR method were applied voltage = 100 V, pulse-on time = 3 ms, Electrolyte concentration = 18% wt/vol. and disc rotation speed = 30 rpm. The present work can provide a productive solution for cutting of difficult-to-cut materials. Thus, in future, the GA-RD-ECDM process can be investigated for other advanced materials (i.e., glass, polymer composites and ceramics) for fabrication of microchannels for microfluidic applications.

中文翻译：

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Al-6063 SiCp MMC切削过程中磨削辅助转盘ECDM的性能评估及多响应混合优化

金属基复合材料 (MMC) 因其高强度重量比而被用于许多应用，包括航空航天、造船和国防工业。然而，这些材料的加工仍然具有挑战性，需要先进的加工技术。目前的研究旨在分析在切削 Al-6063 SiCp MMC 过程中，磨削辅助旋转盘-电化学放电加工 (GA-RD-ECDM) 工艺的性能。进行了详细的实验来研究能量相互作用行为和输入过程变量的影响，即。施加电压、脉冲接通时间、电解质浓度和圆盘转速对性能指标的影响。选择的响应是锥度、过切 (WOC) 和材料去除率 (MRR)。实验工作采用响应面法进行。通过方差分析（ANOVA）开发和统计分析回归模型。最终，GA-RD-ECDM 过程使用多准则决策的 VIKOR 方法进行优化，同时考虑精度和生产率，以获得最小锥度和 WOC 和最大 MRR。ANOVA 的结果显示输入变量具有统计学意义。外加电压对 GA-RD-ECDM 工艺性能的影响最为显着。通过 VIKOR 方法获得的输入过程变量的最佳值是施加电压 = 100 V，脉冲开启时间 = 3 ms，电解质浓度 = 18% wt/vol。和圆盘转速 = 30 rpm。目前的工作可以为难以切割的材料的切割提供有效的解决方案。因此，在未来，可以研究 GA-RD-ECDM 工艺以用于制造用于微流体应用的微通道的其他先进材料（即玻璃、聚合物复合材料和陶瓷）。