A hybrid GRA-PCA-TOPSIS Technique Optimization of EDD Process Parameter on Drilling of AL8011/B4C/aloevera composites

A class of cutting-edge materials called hybrid aluminum metal matrix composites has been produced for applications such as the automobile, aerospace, and electronics industry and where weight and strengths are crucial factors. In the present research work, AA8011 composite reinforced with boron carbide particles and green aloevera has been fabricated using an economical stir casting process. In this 1% to 3% of boron carbide and 1% to 2% aloevera were used to fabricate the three different combinations of composites. The electrical discharge drilling process variables such as discharge current, pulse-on time, pulse-off time, and dielectric fluid pressure are investigated using the tubular copper electrode on drilling of hybrid composites. Performance aspects including drilling rate, roundness error, taper angle, and electrode wear rate have been analyzed, and the effect of process variables with the response surface methodology–central composite experimental design. The process parameters during the drilling of composites were optimized using a novel multi-criteria decision-making technique called the hybrid grey relational analysis–pulse component analysis–technique for order of preference by similarity to ideal solution method in order to maximize the drilling rate while concurrently minimizing other aspects. The optimum conditions were reached using the hybrid optimization method and a 1.5 mm tubular copper electrode with an input current of 9 Ampere , pulse on time 25  μ s, pulse off time 12  μ s, and pressure 60 kg/cm². In comparison to the initial settings, the optimal condition shows a 25% faster drilling rate, with a 23% better roundness value, 14% lesser taper angle, and 7% lesser electrode wear rate.