Processing of functionally graded aluminum composite brake disc and machining parameters optimization

This study aims at fabrication and characterization of silicon carbide reinforced functionally graded aluminum composite brake rotor disc by centrifugal casting and optimization of machining parameters such as tool speed, feed, point angle and machining zones with varying volume fraction of reinforcements during drilling of brake disc using Grey Relational Analysis (GRA). The functionally graded structure is formed in the brake disc by centrifugal casting process, where the centrifugal force migrates the hard SiC particles from inner region of disc towards outer braking areas of the discs, which enhances the hardness, strength and wear resistance. The characterization of brake disc shows higher hardness and compression strength towards the braking area closer to outer periphery due to enrichment of SiC particles. The optimization of machining parameters is very much important in functionally graded material (FGM) components, since the hardness and properties vary at different zones. The tool feed rate and zones of the FGM brake disc are the major factors that significantly influences the drilling process. (C) 2019 Elsevier Ltd. All rights reserved.