Grey Fuzzy Analysis

Optimization of Machining Parameters of A7075 Hybrid MMC

V.Venkata Reddy
K.Srinivasulu Reddy
M.Gopi Krishna

Mechanical Engineering Department

Acharya Nagarjuna University

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Table of Contents

Introduction...............................................................................................................3
2. Experimentation description..................................................................................4
3. Methods.................................................................................................................6
3.1 Grey Relational Analysis (GRA)......................................................................6
3.2 Fuzzy inference system....................................................................................7
3.3 Steps for the gray fuzzy logic method..............................................................8
3.4 Analysis of variance.........................................................................................9
4. Results & Discussions...........................................................................................9
4.1 Calculating the grey relational coefficients......................................................9
4.2 Grey Reasoning Analysis...............................................................................10
5. Conclusion...........................................................................................................14
References...............................................................................................................16

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Introduction

Metal matrix composites (MMCs) offer interesting opportunities for new product design due to enhanced
properties. Some of the beneficial properties of MMCs are high strength and stiffness, increased wear
resistance, lower coefficient of thermal expansion and dimensional stability at a higher temperature. In
aluminum metal matrix composites (AMCs), the matrix material is aluminum alloy and the other phases
are reinforcement which are Gr, SiC, Al2O3, B4C, etc [1,2]. The incorporation of ceramic particles in Al
alloy increases both mechanical strength and wear resistance of the composite. The hard abrasive SiC
particles in Al−SiC composite complicate the machining operation. Thus the machinability of particulate
MMCs is improved by reinforcing soft particles like graphite along with hard ceramic particles [4]. The
composites with combined reinforcement of SiC and Flyash particles are referred to Al−SiC−FA hybrid
composite. The superiority of Al−SiC−FA composite is self-lubricating property, enabled by the presence
of flyash particles and its strength is enhanced by SiC ceramic phase. This hybrid composite substitutes
materials for pistons, cylinder liners, brake drums in automotive and aerospace applications [5, 6].
Isik and kentli [7] proposed a multiple criteria optimization approach using sensitivity. Minimizing
cutting forces and maximizing the material removal were considered as objectives, while turning
of unidirectional glass fiber reinforced polyester rods. Palanikumar used grey relational grade &
Taguchi method for minimizing toolwear, surface roughness and specific cutting pressure, while
maximizing material removal. They carried out turning on GFRP/Epoxy composites using carbide (K10)
tool. Krishnamoorthy applied grey fuzzy logic for optimization of drilling process parameters of carbon
fibre reinforced plastic composite plates. Rajmohan used grey fuzzy algorithm to optimize the machining
parameters, while drilling of hybrid aluminum metal matrix composites. It was reported that feed rate is
the most influencing parameter followed by depth of cut and cutting speed for quality characteristics like
surface roughness (Ra) and material removal rate (MRR) on turning of A356/5 wt. % SiCp, Pradhan and
Sahoo reported that the most significant parameter for surface finish is feed, followed by cutting speed
and depth of cut, during turning of SiC reinforced AMMCs with uncoated carbide inserts. Ciftci observed
uncoated carbide tools produced better surface roughness values when compared to the coated carbide
tools, during turning of Al 2014/SiC MMCs in dry machining condition. Present investigation is focused
on turning performance of A7075/Fly ash/SiC AMMC in terms of Ra and MRR under dry machining
condition with uncoated carbide tipped tool inserts.

The investigation based on fuzzy-logic finds applications in unclear and undecided environment. In the
recent research trends, fuzzy-logic-based multi-criteria decision making techniques have become very
popular in doing optimization of different manufacturing processes. Grey system initiated by Deng[14]is
a powerful tool to deal with the poor, incomplete and vague data[15,16].In recent years, researchers have
effectively used grey relational technique for solving the intricate interrelationships between the multiple
objectives in a variety of fields of manufacturing[17–20].A grey relational grade (GRG) is calculated by
doing average of the grey relational coefficient of each response to convert the optimization of the
complex performance characteristics into optimization of a single GRG[18]. Lin and Lin [20] researchers

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have done optimization of EDM process of SKD11 alloy steel with many process responses using grey-
fuzzy-logic method.

2. Experimentation description
The weight of AMMCs having 10 % of SiC and Fly ash particles of size 53μm were fabricated by stir
casting route are taken as reference for machining as at this percentage, better mechanical properties were
analyzed by Venkata Reddy.

The composites were prepared by stir casting route. Melting of A7075 ingots was performed in an electric
furnace with graphite crucible. At 770°C, molten metal pool is stirred in the middle of the crucible using a
mechanical stirrer at 500 rpm. SiC and flyash particulates are preheated and dropped uniformly into the
melt. To avoid the agglomeration, smooth and continuous flow of the particles is ensured during stirring.
As the casting is exposed to the atmosphere during the stirring, Argon inert gas shielding is maintained
throughout for 2 to 3 minutes to avoid oxidation. Then, molten metal is poured into cast iron molds which
is preheated to 200 0C. The fabricated ingots were kept in a muffle furnace at 110 0C for 24 hours to
remove any residual stresses induced in the castings and to reduce the chemical inhomogeneity.

Uncoated tungsten carbide inserts are used as cutting tool. Rough turning on fabricated ingots is first
performed on Lathe machine to make specimens of uniform diameter as shown in figure 1. Initially, based
on the available feeds, and speeds on the Lathe, pilot experiments were conducted to find the range of
feeds and speeds for good surface finish and material removal rate. After identifying the levels for cutting
speed, feed and depth of cut, Taguchi’s L16 orthogonal array is selected for the design of experiments.
Factors and their levels selected are given in Table 1.

Table 1: Factors and levels selected

Levels of Factors
S.No Factor Notation Unit
Level 1 Level 2 Level 3 Level 4
Cutting
1 N rpm 400 800 1200 1600
Speed
2 Feed f mm/rev 0.05 0.10 0.16 0.20
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3 Depth of cut d mm 0.2 0.4 0.6 0.8

Figure 1: Specimens of A7075 reinforced with flyash and SiC.

Average surface roughness (Ra) of 16 specimens was measured with Surface Roughness
measuring instrument Mitutoyo’s Surf test SJ-210. Surface roughness is measured at three
different locations and average value is taken.

For the productivity evaluation material removal rate was evaluated using the relation given by
the Eq.1 or Eq.2.

MRR=1000vfd mm3/min (1)

(or) MRR = πDNfd, (2)

where N is spindle speed (rpm), v is cutting speed (m/min), D is diameter of the work
piece (mm), f is feed (mm/rev) and d is depth of cut (mm).

3. Methods
3.1 Grey Relational Analysis (GRA)

In GRA, the optimization of multiple response characteristics is converted into single grey
relational grade. The procedure involves: (i) conversion of experimental data into normalized
values, (iii) evaluation of grey relational coefficients and (iv) generating grey relational
grading. In this work it is decided to optimize simultaneously Ra and MRR. Experimental data
sets based on L16 orthogonal array was used.

The response values are normalized to Z ij (i.e., 0< Z ij <1) by using Eq. (3) for smaller the
better type and Eq. (4) is used for larger the better type.
max ( y ij ,i=1 , 2 , … n )− y ij
Z ij = (3)
max ( y ij , i=1 ,2 , … n ) −min ( y ij , i=1 , 2, … n )

where n= number of replications and y ij = observed response value with i =1, 2, ....,n and j
=1, 2,...,k.
y ij −max ( y ij ,i=1, 2 , … n )
Z ij = (4)
max ( y ij , i=1 ,2 , … n ) −min ( y ij , i=1 , 2, … n )

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The grey relational coefficient (ζ) is expressed as the relation between the ideal best and actual
normalized experimental values. It is given by Eq. (5).
∆min+ ζ ∆
ζ(k) = (5)
max

∆ oi k+ζ ∆ max

Where i=1,2,….n; k=1,2,…n; ∆ min = mini min j ‖ x 0 (k) - x i (k)‖; ∆ max =

maxi max j ‖ x 0 (k) - x i (k)‖. The grey relational grade ( ∝i ) is determined by averaging the
grey relational coefficients corresponds to each performance characteristics and it is given by Eq.
(6).

n
1
∝i = ∑ ζ (k) (6)
n k=1
where ∝i is the grey relational grade for the i
th
experiment and k is the number of
performance characteristics.

3.2 Fuzzy inference system

Fuzzy inference system consists of four models: fuzzification interface, rule base and data base, decision
making unit and finally a defuzzification interface [21]. Membership functions of the fuzzy sets defined
by the data base, which are used in fuzzy rules, inference operations on the framed rules is performed by
the decision making unit. Conversion of inputs into degrees of matching with linguistic values is carried
by fuzzification interface; defuzzification interface converts the fuzzy results of the inference into crisp
output [22]. The fuzzy rule base is driven by if-then control rules with the two inputs and one output i.e.,

 Rule 1. If x 1 is A 1 and x 2 is B 1 then y is

C1 else.
 Rule 2. If x 1 is A 2 and x 2 is B 2 then y is
C2 else.
 ….
 Rule n. If x 1 is A n and x 2 is B n then y is
Cn else

A i , B i , Ci are fuzzy subsets which are defined by the membership functions, i.e., μ A i ,
μ Bi , μ Ci .Fig.2 shows the schematic illustration of the fuzzy interface system, based on which
prediction is carried out.

Knowledge Rule base

base

Output Defuzzificaton,
Denormalizatio
Grey Fuzzy Analysis

Fig 2: Fuzzy Interface system

3.3 Steps for the gray fuzzy logic method.

(Grey relational analysis) Fuzzy

Logic Tool
Measurement of Ra Normalize each response considered using Box
and MRR
max ( y ij , i=1,2, … n )− y ij
max ( y ij , i=1,2, … n )−min ( yij , i=1,2,… nCalculation
) of GFRG Value

Calculate the grey relational coefficient

for each response using
∆min+ ζ ∆ Determination of
ζ(k) =
max

∆ oi k+ζ ∆
max
optimal
combination of
n
1 parameters,
Use the formula = ∑ ζ (k) to
n k=1 Response table,
Conformation test and verification of results
Response Graph
and ANOVA

Figure 3: Steps for the gray fuzzy logic method.

The procedure adopted for determining the optimum machining parameters for the multi-response
optimization is shown in Fig. 3. The methodology consists of a six step approach shown below:

Step 1: Preauthorizing the machining parameters and their levels. Perform the experiments by using L16
orthogonal array.

Step 2: Face values of all the responses (Data pre-processing) obtained by using Eq.(3 &4). Calculation of
the grey relational coefficient ζi(k) for each response by using Eq.(5). Eq.(5)was used to generate the
overall grey relational grade α.

Step 3: Fuzzification of the grey relational coefficient obtained from each responses and fuzzification of
the overall grey relational grade by using the membership function. The establishment of the fuzzy rules
in linguistic form relating grey relational coefficient and overall grey relational grade is satisfying.

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Step 4: By using max–min interface operation, calculation of the fuzzy multi-response output and then
employing centroid defuzzification to calculate a grey fuzzy reasoning grade by “Matlab” tool box.

Step 5: Selecting the optimum combination of parameters through the response table and response graph.
Finding the contribution of each factor and their interactions on the multi response output by using
analysis of variance (ANOVA) was anticipated.

Step 6: Carrying out confirmation tests for verifying the results.

3.4 Analysis of variance.

A statistical technique applied to evaluate the difference among the available set of sources is Analysis of
variance (ANOVA).ANOVA is applied to quantify the contribution of chosen input parameters over the
output response. Inferences from ANOVA table can be used to identify the parameters responsible for the
performance of the selected process and can control the parameters for better performance.

4. Results & Discussions

4.1 Calculating the grey relational coefficients

The pre-processed data of experimental results, the grey relational coefficients and the overall grey
relational grade for each of the combination of parameters is given in Table 2. For surface roughness,
‘lower-the-better’ criterion is preferred and for MRR ‘higher-the-better’ criterion is preferred. On the
other hand, in order to obtain an improved quality in the performances and to decrease the vagueness in
the data, grey-fuzzy logic method is additionally used for computing the GFRG.

4.2 Grey Reasoning Analysis

In this present paper, two inputs and one output (GFRG) fuzzy-logic system is used. The inference engine
(Mamdani fuzzy inference system) performs fuzzy reasoning with fuzzy rules for generating a fuzzy
value. These fuzzy rules are shown in the form of ‘if–then’ control rule. Grey relational coefficients for
Ra, and MRR are inputs to the fuzzy logic system. The linguistic membership function for instance Very
low, Low, Medium and high are used to represent the grey relational coefficients (GRC) of input variables
Ra and MRR. Likewise the output grey relational grade is being represented by the membership functions
such as Very Low (VL), Low (VL), Medium (M), Low, High (H), and Very High (VH). The triangular
shaped membership function, which is used in this work, is shown in Figs. 5 and 6. A total of 16 numbers
of fuzzy rules are used for this purpose. The following 16 fuzzy rules are developed exhibiting the
relationships between the GRC and GFRG values:

 If (Ra is VL) and (MRR is VL) then (GFRG is VL)

 If (Ra is VL) and (MRR is L) then (GFRG is L)

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Grey Fuzzy Analysis

 If (Ra is VL) and (MRR is M) then (GFRG is L)

 If (Ra is VL) and (MRR is H) then (GFRG is L)
 If (Ra is L) and (MRR is VL) then (GFRG is L)
 If (Ra is L) and (MRR is L) then (GFRG is L)
 If (Ra is L) and (MRR is M) then (GFRG is M)
 If (Ra is L) and (MRR is H) then (GFRG is M)
 If (Ra is M) and (MRR is VL) then (GFRG is L)
 If (Ra is M) and (MRR is L) then (GFRG is M)
 If (Ra is M) and (MRR is M) then (GFRG is M)
 If (Ra is M) and (MRR is H) then (GFRG is M)
 If (Ra is H) and (MRR is L) then (GFRG is M)
 If (Ra is H) and (MRR is M) then (GFRG is M)
 If (Ra is H) and (MRR is H) then (GFRG is VH)
 If (Ra is H) and (MRR is VL) then (GFRG is M)

The rule-based fuzzy-logic reasoning is shown in Fig. 7. Maximum–minimum compositional operation

by tracking the fuzzy reasoning yields a fuzzy output. At last, the defuzzifier converts the fuzzy predicted
values into a GRFG by using MATLAB (R2018b) fuzzy logic toolbox. This GFRG values are tabulated in
Table 2.
The higher values of GFRG exhibits the best multiple performance characteristics. Analysis of the mean
is performed for GFRG. On the basis of Δ (Delta) statistics, which is the difference among the highest and
the lowest average of GFRG for each of the factor, the rank of the parameters, which affects the multiple
performance response, is listed in Table 3. These values are plotted in Fig. 8 like the response graph for
the machining parameters. The greater the inclination of the response graph, the larger the effect of the
process parameters on the multiple performance response.

Table 2. Data pre-processing, grey relational coefficients and grey relational grades.

Fig. 5 is drawn to show the fuzzification of the three inputs e.g. Ra (taking their grey relational coefficient
value). The triangular membership function graph is shown to define how the values of the input and
output (Y=GFRG) are mapped to a value between 0 and 1. The linguistic membership function such as
VERY LOW, LOW, MEDIUM, and HIGH are used to represent the grey relational coefficient (GRC) of
input variables. Similarly, the output grey relational grade is represented by the membership functions
such as VERY LOW (VL), LOW (L), and MEDIUM (M), HIGH (H), and VERY HIGH (VH) .The
triangular shaped membership function used in this work is shown in Fig. 6.

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Fig 5: Membership functions for surface roughness and MRR.

Fig. 6: Membership function for multi-response output

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Fig 7: Fuzzy logic rules viewer.

Table 3: Table of response for grey-fuzzy reasoning grade (GFRG)

Machining
Level 1 Level 2 Level 3 Level 4 Delta Rank
Parameters
Cutting Speed (A) 0.5147 0.5668 0.5765 0.6397 0.125 1

Feed Rate (B) 0.5767 0.6112 0.5533 0.5565 0.058 3

Depth of Cut (C) 0.5242 0.5785 0.5938 0.6012 0.077 2

Fig. 8: Response graph for every level of machining parameters

Based on Table 3 and Fig. 8, the optimum setting of the machining process parameters is found to be
cutting speed at level four (1200 rpm) (A4), feed rate at level two (0.10 mm/min) (B2) and depth of cut at
level four (0.80 mm) (C4). The use of these conditions will at the same time minimize the Ra and
maximizing the MRR throughout machining within the range of factors studied. The response equation of
the GFRG is shown in Eq. (7). The main influencing factor for multi-performance is the maximum of this
value (i.e. rank 1), which is cutting speed (A). Also the same information can be obtained from Fig. 8.

GFRG = 0.6313 - 0.000068 A - 0.957 B - 0.316 C + 0.000000 A*A - 3.49 B*B - 0.292 C*C
+ 0.000346 A*B + 0.000328 A*C + 3.414 B*C (7)

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ANOVA is performed for analyzing the role of each factor on the multiple performance characteristics.
The analysis is done at a confidence level of 95%. Fisher’s F-test is employed to find out the change in
which the process parameters have a significant effect on multiple performance characteristics. Larger F-
value shows that the change of process parameters has a stronger influence on the performance
characteristic. The results of the ANOVA are shown in Table 4. As in the ANOVA table of GFRG, the
percentage contribution of the cutting speed is 43.43. This indicates that the cutting speed played a main
role to determine the GFRG
The obtained results are verified by the confirmatory experiment. Table 5 shows confirmation results of
surface roughness and MRR corresponding to initial and optimal machining conditions. It is evident that
machining with the optimal parametric combination would minimize Ra form 12.452 to 6.954mm, MRR
from 0.0210 to 0.0202mm/mm2. The estimated or predicted GFRG ( Y ) at the optimum level of the
machining parameters can be calculated by Equation (8)
Y −¿
i
¿
Y = Ym + q - Y m ) (8)
∑¿
i=1
−¿¿
Where Y m the mean of GFRGs for is all experimental runs and Yi is the mean of GFRG at the

optimum level of i t h parameter, and q is the number of machining parameters that significantly affect
GFRG.
Table 5 also indicates that the machining with optimal setting would result in an improvement of GFRG
of 0.2119 and 0.2341 for experimental and predicted values respectively. Therefore, the current study
clearly demonstrates that grey-fuzzy-logic method combined with Taguchi-based design of experiment is
a useful technique with smaller number of experimental trials and for ease in optimizing multi
performance characteristics of machining of Al7075 hybrid metal matrix composites.

Table 4: ANOVA for GFRG

F- P- Contributio
Source DF Seq SS Adj MS
Value Value n
0.02960 0.00507
A 1 0.56 0.484 43.43%
7 7
0.00309 0.00817
B 1 1.83 0.225 4.54%
5 0
0.01212 0.01045
C 1 3.02 0.133 17.79%
8 8
0.00012 0.00243
A*A 1 0.31 0.596 0.19%
7 2
0.00152 0.04124
B*B 1 2.67 0.154 2.24%
6 3
0.00218 0.00004
C*C 1 5.4 0.059 3.21%
6 1
0.00113 0.04196
A*B 1 1.03 0.350 1.66%
2 0
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0.00580 0.05039
A*C 1 14.34 0.009 8.52%
6 3
0.01014 0.00111
B*C 1 25.06 0.002 14.88%
4 0
0.00242 0.00040
Error 6 3.56%
8 5
0.06817
Total 15 100.00%
8

Table 5: Conformation Experiments.

5. Conclusion
In this present paper, machining of Al–10%FA/SiC metal matrix composite is carried out with input
parameters considered as cutting speed, feed and depth of cut, and the response parameters as surface
roughness, and MRR in lathe machine. Taguchi’s L16 orthogonal array design is used for performing
turning operation on the composite.
 It was found that a cutting speed of 1600 rpm, feed of 0.1 mm/min and a depth of cut of
0.80 mm is the optimal combination of input parameters.
 ANOVA statistics exposed that cutting speed is the most influencing factor in effecting
the response parameters
 Therefore, it is concluded that the optimization procedure proposed in this present paper
significantly improved the production of turning of Al–10%FA/SiC metal matrix composite.
The influence of the machining parameters over surface roughness and material removal rate are
investigated experimentally in this work. The optimum conditions are obtained by using a hybrid grey
fuzzy algorithm. The grey relational analysis and fuzzy logic are coupled to obtain a grey fuzzy grade for
evaluating multi characteristic output from the grey relational coefficient of the each response. The
experiments were designed using Taguchi’s design of experiments; a L16 orthogonal array was selected
for three parameters varied through four levels. Fuzzy based reasoning was integrated using the grey
approach to reduce the degree of uncertainty. The optimal setting was found by a response table and the
influence of input parameters on the output were determined by analysis of variance. With help of this
hybrid technique the performance characteristics of the machining process were improved, which is
proved by the results from the conformation experiment.

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