Mathematical Modeling of Wear Characteristics of 6061 Al-Alloy-SiCp Composite Using Response Surface Methodology

In the light of attractive wear characteristics as well as high strength to weight ratio, extensive research on Al-based Metal Matrix Composite (MMC) have been carried out globally in the last two decades. However, very limited research has been pursued on tribological behavior of Al-based MMC under combined action of rolling and sliding. This study investigates the wear behavior of 6061 Al-alloy/SiC with 10 vol.% SiCp against hardened and tempered AISI 4340 steel under combined rolling-sliding conditions. 2³ factorial design of experiments have been carried out to see the effect of few parameters, i.e., contact stress, speed and duration with respect to wear. The interaction effect has also been studied by 3D graphical contours. A mathematical model is developed using regression analysis technique for prediction of wear behavior of the MMC and adequacy of the model has been validated using analysis of variance (ANOVA) techniques. Finally, the optimization of parameter has also been done using Design Expert software. The results have shown that Response Surface Methodology (RSM) is an effective tool for prediction of wear behavior under combined sliding and rolling action. It is also found that the wear of MMC is much lower than hardened; tempered AISI 4340 steel and rolling speed has the maximum influence in wear of both materials under investigation.