Investigate the Deformation Behavior of Reinforced 7075 Aluminium Metal Matrix Composite through Cold Extrusion Process for Automobile Brake Caliper

Abstract

The research studied on the comprehensive studies of fabrication and characterization of SiC, CeO2 and GO-7075Al-hybrid composite with improved mechanical and triabological behavior. The two-step approach includes an initial stir casting process SiC, CeO2 and GO hybrid reinforcements, followed by a cold extrusion step to further optimize the material's microstructure and performance. Three different hybrids aluminum composite was fabricated and Ce analyzed with altering the reinforcement +5%SiC+4%GO,81%Al7075+7.5%Ce ratio 81%Al7075 +10% +7.5%SiC+4%GO,and81%Al7075+5%Ce +10%SiC+4%GO with 650rpm stirring speed for 10 minute through maintaining the stirring temperature of matric 700 . The optimum string parameter was selected to accomplish a homogeneous distribution of the hybrid reinforcements within the aluminum with homogenous distribution of reinforcement melt. The casted composites show the improvement in mechanical and tribological properties when compare to the pure alloy due to uniform distribution of reinforcement. The 81%Al7075+7.5%Ce +7.5%SiC+4%GO hybrid composite show highest hardness, compression strength 240.5HV (66.25%improvement ) 490MPa,respectivelyas well low wear and corrosion rate was recorded. 81%Al7075+7.5%Ce+7.5%SiC+4%GO composite were chosen using Grey Relational analysis (GRA) method depend on the properties for secondary operation. The plan and design of experiments was performed by Box Behnken method at three factors and levels The DEFORM 3D software was used for the numerical simulation of cold extrusion at varies parameter: extrusion ratio (6, 8, and 10), ram speed (2.5, 3, and 3.5) m/s, and (185,225,265) .The surface response methodology in Design expert was used the predicted the box behken method combined damage, extrusion load and effective stress from simulation with input extrusion parameter. The result showed significance and further optimized by genetically algorithm using mat lab. The optimum extrusion ration of 6, ram speed of 2,5m/s and temperature of 265 was used to real deform the sample and the post deformation test showed the further improved in properties.