International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 04 | Apr-2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 1994 Development of Al-SiC MMC by bottom pouring stir casting and parametric analysis on EDM Jay A. Patel 1 , Chirag P. Patel 2 1 Post Graduate Scholar, Department of Advanced Manufacturing Systems, U.V. Patel College of Engineering, Ganpat University, Mehsana, Gujarat, India 2 Associate Professor, Mechanical Engineering Department, , U.V. Patel College of Engineering, Ganpat University, Mehsana, Gujarat, India. --------------------------------------------------------------------------***---------------------------------------------------------------------------- Abstract - Development of metal matrix composite (MMC) to study about the microstructures, hardness of as cast silicon carbide (SiC) reinforced with aluminum metal matrix composite. Aluminum (HE 30) and Silicon carbide reinforced particles metal-matrix composites (MMCs) were fabricated by bottom pouring stir casting technique. The MMC are prepared with varying the reinforced particles of SiC by weight fraction ranging from 10,15,20 in percentage. The average reinforced particles sizes of SiC is 400 mesh. Hardness for all cast composite and microstructure of Al-15% SiC composite are analyzed. Non-conventional processes such as electrical discharge machining (EDM) could be one of the best suited methods to machine such composites. Prepared specimens of Al-SiC MMC are used as work piece (anode), copper electrodes are used as tool (cathode) and kerosene oil is used as the dielectric fluid. Four machining parameters such as discharge current I (5,12,20 Amp), pulse on time (100,500,1000 µs), gap voltage Vg (10,20,30 Volts) and material property weight fraction of SiCp (10,15,20)and responses like material removal rate (MRR), tool wear rate (TWR), and surface roughness (Ra) are considered in this study. Taguchi method is adopted to design the experimental plan. The influence of each parameter on the responses is established using analysis of variances (ANOVA). Key Words: Metal matrix composite, stir casting, hardness, Microstructure, Electrical discharge machining, Anova 1. INTRODUCTION Composite materials play an important role in the field of engineering as well as advance manufacturing in response to unprecedented demands from technology due to rapidly advancing activities in aircrafts, aerospace and automotive industries.[1] There are two major reasons for the current interest in composite materials. The first is simply the need for materials that will outperform the traditional monolithic materials. The second and more important in the long run is that composite offer engineers the opportunity to design totally new materials with the precise combination of properties needed for specific tasks.[2] 1.1 Al-SiC MMC Aluminum is used widely as a structural material especially in the aerospace industry because of its light weight properties. Its low strength and low melting point of aluminum were always a problem. An effective method of solving these problems is to use a reinforced element such as SiC particles and whiskers. The main objective of using silicon carbide reinforced aluminum alloy composite system for advanced structural components to replace the existing super alloys. 1.2 Stir casting process In a stir casting process, the reinforcing phases are distributed into molten matrix by mechanical stirring. Stir casting of metal matrix composites was initiated in 1968, when S. Ray introduced alumina particles into aluminum melt by stirring molten aluminum alloys containing the ceramic powders. Mechanical stirring in the furnace is a key element of this process. The resultant molten alloy, with ceramic particles, can then be used for die casting, permanent mold casting, or sand casting as shown in figure 1. Fig - 1: Process of Stir Casting [3]