Machinability of LM 25 cast composites using hybrid nano coolant: optimization of cutting parameters by RSM and evolutionary algorithm

Abstract

The research topic is selected to address the performance of LM 25 AHMMC cast composites. The selected material is widely utilised in automobiles, aerospace, and marine parts as an alternative to piston material. The cast composites are prepared by reinforcement of nTiO2, nZrO2, and bagasse ash materials in different combinations of wt% to LM 25. The 84% LM 25, and 5% nTiO2 + 3%nZrO2 + 8%bagasse ash combination exhibits 96.20 HV microhardness with an improvement in hardness by 38.76 HV compared to the base alloy. The objective of the research is to study the surface roughness, rate of material removed, insert tip temperature, flank wear, and feed force in the turning process. The RSM is used to develop the test combinations using speed, feed, hardness of cast composite, and cooling environment as variables in three levels by keeping depth constant. The soybean oil is utilised to prepare nano coolant by concentrating the nTiO2, nMoS2, and nZnO materials with different wt% combinations used in MAC condition. The TiCN- and Al2O3-coated inserts are used to investigate the performance in terms of flank wear. The variables are analyzed by statistical tools DFA and RSM and soft tools MOGA, MOPSO, and MONSG2. The lowest SR of 2.4 μm, 32.59 °C of ITT, and 1.2 kgf feed force are generated by MOGA for M1, M3, and M1 cast composites, respectively, for the NC-2 cooling environment, and 0.0032 mm flank wear by MOPSO for M2 and cast composites in the NC-1 cooling environment are studied through the Pareto front.