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CHAPTER 3
MATERIALS AND METHODS
3.1
INTRODUCTION
Based on the literature survey and research objectives discussed in
PLAN OF INVESTIGATIONS
The plan of investigations is shown in Figure (3.1). Important
following headings.
the
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3.3
MATERIALS
In the present study, composites have been developed to evaluate
Matrix material
The desirable properties required for aluminium alloy matrices are
Si
Fe
Mn
3.3.2
Cu,Ni,Zn,Pb,Sn
andTi
Al
1.5 max
Balance
Reinforcements
Reinforcement is the material, which is added to improve the
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disulphide (MoS2) contribute to lowering wear rate, friction and increasing
seizure resistance.
In the present study, both hard and soft reinforcement has been
used to produce composites. SiCp reinforcement with an average particle size
of 40 m with a density of 3210 kg/m3 was used to produce the composite.
The melting point of the SiC is 2890 C, has a very low reactivity in molten
metal and is relatively cheap. A significant enhancement in composite
properties, such as stiffness, strength and fracture toughness, as well as low
reactivity and the low cost make this reinforcement ideal for the manufacture
of cast metal matrix composites requiring very good wear resistance.
Molybdenum disulphide, a solid lubricant has been used as a soft
reinforcement in this research. The average particle size of MoS2 used was
1.5 m and has a density of 4800 kg/m3. Lubrication effectiveness /efficiency
of MoS2 often exceeds that of graphite and are effective in a vacuum where
graphite fails. However, the efficiency of MoS2 lubrication decreases after
675 K wherein it begins to form MoO3, which lowers the lubricating effect.
MoS2p have superior load bearing and surface speed performance values in
comparison to either graphite or tungsten disulphide.
3.4
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The molten mixture was solidified in a cast iron die in the form of cylindrical
pin of a diameter of 15 mm and length of 75 mm. In the present work, AlSi10Mg MMCs reinforced with 10 wt. % and 20 wt. % SiCp were produced.
The same procedure was repeated for to produce AMCs reinforced with 2 wt.
% and 4 wt. % MoS2p. Hybrid metal matrix composite with 2 wt. % and 4 wt.
% of MoS2p and with 10 wt. % and 20 wt. % SiCp were also cast. As cast
composites and machined wear pin, samples shown in Figure 3.3.
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MICROSTRUCTURAL CHARACTERISATION
Microstructural characterisation of the composite specimens was
carried out using Carl Zeiss Goettingen Optical microscope. The specimens
were metallographically polished as per standards to obtain average
roughness value of 0.8 m. The specimens were etched with 2% hydrofluoric
acid. Optical micrographs of the polished specimens were recorded at
different magnifications.
3.6
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3.6.1
Density measurement
Density of composites as well as matrix alloy was determined using
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Morphology studies
Morphology of fractured surface as well as the worn surface of the
composite specimen for tensile test was carried out using JEOL JSM 6360,
T100 Scanning Electron Microscope (SEM). Surface morphology was studied
different magnifications.
3.6.5
conducted as per ASTM G-99 standard. Initial and final weight of the
specimen was measured using a Mitutoyo make electronic weighing machine
with an accuracy of 0.0001 g. Wear tests were conducted on 10 mm diameter
and 25 mm long cylindrical specimens against a rotating EN-32 steel disc
(counter face) having a hardness 65 Rc. The difference in weights before and
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after the test was taken as weight loss. Each test was repeated three times and
the results were averaged. Wear Rate (WR) of the composites was studied as
a function of sliding velocity, applied load and sliding distance. WR was
calculated based on the difference in weights of the specimen using the
Equation (3.1) for a constant sliding distance of 3000m.
[
]=
(3.1)
Figure 3.5
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Table 3.2 Specifications of the Tribo-system
Make
Testing Standard
: ASTM G99
Pin size
: 3 12 mm
Disc size
: 100 mm x 8 mm thick
Sliding velocity
: 0.26 10 m/s
: 200 N
Frictional force
: 0 200 N
3.6.6
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3.7
INTEGRATED
RESPONSE
SURFACEGENETIC
Design of Experiments
Measurement of the Material Property
Development of Response Surface Model(s) (RSM)
Analysis of Variance (ANOVA)
Formulation of Fitness function from RSM
Optimization using Genetic Algorithm
Confirmation Experiment(s)
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RSM-GA is a blend of experimental design, statistical method and
optimisation technique for constructing an empirical model and for achieving
optimum conditions. The procedure for RSM-GA is shown below
Step 1:
Step 2:
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Step 4:
independent
Y=f(X1,X2,...,Xn) +
variables,
where
X1,X2,...,Xn
as
follows.
is
f(X1,X2,...,Xn)
by
suitable
lower-ordered
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The aim of using RSM is not only to examine the response over the
whole factor space, but also to find the region of importance where
the response attains its optimum or near optimal value. By carefully
examining the response surface model, the combination of factors,
which offer the best response, can then be determined. The values
of the regression coefficients of the linear, square and interaction
terms of the RSM models can be determined by using the relation.
B (X T X ) 1 X TY
(3.2)
Error %
100
n
n
i 1
Y Exp i Y Pr ed
Y Exp i
(3.3)
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given experiment. The F-test is simply a ratio of sample variances.
Comparing the F-ratio of a source with the tabulated F-ratio is
called the F-test. When Analysis of Variance has been performed
on a set of data and the respective sums of squares have been
calculated, it is possible to use this information to distribute the
corrected sums of squares to the appropriate factors. Comparing
this value with the total sum of squares, gives the percent of the
contributions of each factor can be obtained. The percent
contribution due to error provides an estimate of the adequacy of
the experiment. Since error refers to unknown effects and which
cannot be controlling factors, the percent contribution due to error
suggests that if the sufficiency due to error is low (15% or less),
then it can be assumed that no important factors have been omitted
from the experiment.
Step 6:
Step 7:
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Coding Structure
The primary step in GA is to decide the coding structure. A set of
coding structure is termed as a chromosome. Each individual
chromosome is usually described as a string of symbols from
(0,1) which are labelled as Genes. The number of bits that must
be used to describe the parameters is problem dependent. Let
each solution in the population of N such solutions Xi, i=1, 2, .. .,
N, be a string of symbols (0,1) of length L. The length of L is
determined by the number of variables affecting the optimum
solution. The relationship between phenotype and genotype of
individual chromosome is shown in Figure 3.9.
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wheel, Uniform selection and Tournament selection are available.
Among them Roulette wheel selection is one of the most widely
used scheme in the selection process. It is a probabilistic selection
method, which is based on the individuals fitness such that the
better individuals have an increased chance of being selected. In
this scheme, parent selection is based on roulette wheel where
each member of the population is represented by a slice whose
size is decided by members fitness. A selection step is then a
spin of the wheel, which in the long run tends to eliminate the
least fit population members. The probability P, for the individual
selection is defined by :
P[X isc hosen] =
)
)
>0
(3.4)
(iv) Reproduction
Reproduction options control how the Genetic Algorithm creates
the next generation. The reproduction options used by the GA are
Elite chromosome, Cross over chromosome and Mutation
Chromosome. The reproduction consists of basically three steps.
a. Selection
Elite Chromosomes are specified by the number of individuals
with the best fitness values namely Elite Count (Ne) in the current
generation, which are guaranteed to survive to the next
generation. The Elite Chromosome fraction of the next generation
population (N) is
P =
(3.5)
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Setting Ne to a high value causes the fittest individuals to
dominate the population, which can make the search less
effective. Besides Elite Chromosome, GA uses the individuals in
the current generation to create the children that make up the next
generation namely, Cross over Chromosome and Mutation
Chromosome. Crossover takes genes from a pair of individual
chromosome (parents) in the current generation and combines
them to form a pair of children (Cross over Chromosome 1 and
Cross over Chromosome 2).
b. Crossover
The number of Cross over Chromosome in the next generation is
termed as Cross over Count (Nc). Crossover fraction is Pc which
ranges from 0 to 1. A random number R is generated and
compared with the probability parameter Pc. If the random
number is less than Pc, a crossover operation is selected,
otherwise, no crossover is performed and the individual parent is
returned. If the crossover operation is selected, then a random
number called the crossover point Rc is generated between 1 and
length of the chromosome Lc.
functions are available like one point crossover, the two point
cross over and heuristic cross over and so on . One-point
crossover is one of the popular crossover methods wherein a pair
of children chromosome is formed by interchanging the last Lc
Rc elements of the first parent chromosome and last Lc
elements of the second parent chromosome.
Rc
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3.8
SUMMARY
Wear processes in composites are a difficult phenomenon