Machinability and surface morphology investigations of multiwall carbon nanotube reinforced aluminium 7075 metal matrix composite during electrical discharge machining: A grey relational approach

Multiwall carbon nanotube buttressed aluminium 7075 metal matrix composite was synthesized through an amended liquid metallurgy method, which consisted semisolid stirring, ultrasonic treatment and squeeze casting. Aim was to investigate its machinability and surface morphology during electrical discharge machining. Variable machining factors were peak current, pulse-on time and gap voltage, whereas the responses under investigation were electrode wear rate, material removal rate and average surface roughness. Results revealed electrode wear rate, material wear rate and average surface roughness increased on increasing peak current and pulse-on time, but all these responses behaved inversely with the increase of gap voltage. Average surface roughness reduced by around 44% on reducing the peak current from 10 A to 4 A and increasing gap voltage from 55 V to 80 V at constant pulse-on time of 300 μs; however, it increased by around 25% on reducing the gap voltage from 80 V to 55 V and increasing the pulse-on time from 100 μs to 300 μs at constant peak current of 10 A. Significance of the process parameters were verified, regression models were developed and morphology of the machined surfaces was studied. Finally, multiple response optimization was conducted following grey relational approach.