(IJCSIS) International Journal of Computer Science and Information Security,
Vol. 9, No. 3, March 2011
Modeling of Aluminium – Flyash Particulate
Metal Matrix Composites using Fuzzy Logic
1
R.Elangovan and 2Dr.S.Purushothaman
1 2
R.Elangovan, Research Scholar,
Department of Production Engineering,
Vinayaka Missions University, Salem, India-636 308
Abstract--This paper models the tension and bend test
data using fuzzy logic and radial basis function (RBF)
artificial neural network. The data have been collected
experimentally working on Aluminium–flyash metal
matrix composite. The fuzzy logic estimates change in
height in tension test and change in buldge diameter in
bend test better when compared to RBF.
Keywords: Radial basis function, fuzzy logic, tension test,
bend test, scanning electron microscopy
I. INTRODUCTION
Composite materials are engineered materials
made from two or more constituent materials with
significantly different physical or chemical properties
and which remain separate and distinct on a
macroscopic level within the finished structure. Metal
Matrix Composite (MMC) consists of a metallic
matrix combined with a reinforcing material. The
matrix materials are Aluminium, Magnesium,
Titanium[1-3]. The reinforcing materials can be
flyash, Silicon Carbide, Graphite, and Alumina
Al-flyash composite has low density. This
composite has potential applications in covers,
shrouds, casings, manifolds, valve covers, garden
220
Dr.S.Purushothaman, Principal,
Sun College of Engineering and Technology,
Sun Nagar, Erachakulum, Kanyakumari District –
629902, India
Email: dr.s.purushothaman@gmail.com
furniture, and engine blocks in the automotive, small
engine and electro mechanical industry sectors.
Flyash can be classified into two categories,
precipitator and cenosphere. Precipitator flyash is a
solid and has a density of about 2- 2.5 gm /cm3.
Cenosphere flyash is hollow and has a lower density
of about 0.6 gm/cm3. Flyash have been used as the
reinforcing particulates in aluminium matrix [4-6]. Flyash
has received attention as reinforcing phase as it is found to
increase the hardness, tensile strength and wear resistance of
aluminium metal matrix composites.
Particulates are the most common and cheapest
reinforcement materials. These produces the isotropic
property of MMC's which shows promising application in
structural fields The Al - flyash - silicon carbide hybrid
matrix composites have a good potential for use as wear
resistant materials. Flyash particulate improves properties
such as hardness, wear resistance and compressive strength.
If the composite is to be used in a structural application, the
modulus, strength and density of the composite will be
important which requires high modulus, low density
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 (IJCSIS) International Journal of Computer Science and Information Security,
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reinforcement like flyash. If the composite is to be used in material is stirred again and again and poured into the
wear resistant applications, hardness is important. moulds. It solidifies. The solid is cut into shapes, and
II MATERIALS AND METHODS the surface is cleaned.

A. Materials
B Methods
A hollow pipe is taken first with a dimension of
B.1 Fuzzy Logic
500 mm long 70mm radius and 8 mm thickness.
Fuzzy logic has rapidly become one of the
Some quantity of water is added to the foundry sand
most successful of today's technologies for
to increase the adhesives and collapsibility of the
developing sophistication in technologies. Fuzzy
sand. After that, a hollow pipe of 40 mm diameter
logic addresses applications perfectly as it resembles
and 500mm long is inserted vertically into the
human decision making with an ability to generate
standing bigger hollow pipe. The gap between the
precise solutions from certain or approximate
pipes is filled with the prepared foundry sand. It is
information. It fills an important gap in engineering
rammed well so as to form the shape of the pattern.
design methods left vacant by purely mathematical
Then it is kept under the sunlight so that it will set
approaches, and purely logic-based approaches in
well. After that, the pattern is removed and the cavity
system design. While other approaches require
is formed on the mould.
accurate equations to model real-world behaviors,
The pure aluminium ingots arc cut into small
fuzzy design can accommodate the ambiguities of
pieces. The coal is heated in the furnace. After the
real-world human language and logic. It provides
sufficient heat is applied blower is switched on.
both an intuitive method for describing systems in
Crucible is placed in the furnace. When sufficient
human terms and automates the conversion of those
amount of heat is obtained in the crucible, aluminium
system specifications into effective models.
pieces are put in. When the crucible reaches about
B.2 Radial basis function (RBF)
600oC, the aluminium pieces melts into liquid. Slag is
Radial basis function is a supervised neural
removed. When the molten metal gets into a semi
network. The network has an input layer, hidden
solid condition, flyash is added to it and is mixed
layer (RBF layer) and output layer. The features
with stirrer. Then it is kept cooled so as to become a
obtained are used as inputs for the network and the
solid composite.
target values for training is based on the values
In stir casting process, the aluminium is melted
change in height or change in buldge diameter.
at a controlled temperature and the desired quantity
Training RBF is done as follows,
of flyash is added to the molten metal. The molten
1. Distance between pattern and centers are
metal is stirred continuously to create a vortex to
found.
force the slightly lighter particle into the melt.
2. An RBF matrix whose size will be (np X
Continuous stirring is done to disperse the flyash
cp). where ‘np’ is the number of patterns
particulate as uniformly as possible in a short time.
used for training and ‘cp’ is the number of
For stirring the flyash and molten metal, three blade
centers which is equal to ‘np’.
propeller type is used. The mixed matrix is then
3. Final weights are calculated.
transformed into a preheated transfer ladle. The

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4. During testing the performance of the RBF test provides information on proof stress, yield point,
network, RBF values are formed from the tensile strength, elongation and reduction in area
features obtained from inputs and processed (Table 1).
with the final weights obtained during
training. Based on the result obtained, the B. Bend test
test data is classified. Testing will be done using a UTM.
Capacity of UTM is 40 tonnes.
III EXPERIMENTAL WORK AND RESULTS Diameter of rod =24mm
Chemical composition of flvash Bending pan radius =16mm
(Data collected from Tuticorin thermal power plant Length of the rod =265mm
Tamil Nadu, India)
Sio2 - 60.62 %, IV RESULTS AND DISCUSSIONS
Al2O3 - 21.93%
A. Estimating change in height during tension
Fe2O3 + Fe304 -
test
7.12%
Figure 1 shows estimation of change in height by
CaO - 2.28%
Fuzzy logic for the tension test data. The estimation
MgO - 0.85 %
is accurate and concides with the original data
So 4 - Traces
collected. Figure 2 shows estimation of change in
Loss on ignition -
height by RBF for the tension test data. The
0.72%
estimation slightly deviates and not close with the
Bulk Density - 0.86gm/cc
actual data.
Fineness - 0.075mm in
m2 / kg Figure 3 presents comparisons of the performance of
Melting point of aluminium is - 660° C RBF and fuzzy logic in estimating the change in
Casting period -2 ½ hrs height. The performance of Fuzzy logic is superior to
Stirring period 20 minutes performance of RBF. However, depending upon the
type of data used, the performance of RBF will
A. Tension test improve further.
A standard test piece is taken.. The gauge
B Estimating buldge diameter during bend
length is maintained by gripping at either end by
test
suitable apparatus in a universal testing
machine(UTM). The UTM slowly exerts an axial pull Figure 4 shows estimation of change in buldge
so that the specimen is stretched until it breaks. The diameter during bend test by Fuzzy logic for the
bend test data. The estimation is almost accurate and for the bend test data. The estimation slightly
coincides with the original data collected. Figure 5 deviates and not close with the actual data
shows estimation of change buldge diamater by RBF Figure 6 presents comparisons of the performance of
RBF and fuzzy logic in estimating the buldge

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Table 1 Tension test performance

Aluminium + Aluminium + Aluminium +
5% flyash 10% flyash 15% flyash
Maximum ultimate 15.94 KN 16.14KN 17.85KN
load
Deflection at 9.9mm 11.7mm 13.3mm
maximum load
Maximum 7.5mm 9.2mm 10.3mm
displacement at
fracture
Percentage of 8.3% 10.2% 12.4%
elongation
Scanning Electron
Microscope
photograph

Table 2 Scanning electron microscope photograph Tension test performance

Aluminium + Aluminium + Aluminium +
5% flyash 10% flyash 15% flyash

13 13
Target Target
12 Estimated 12 Estimated

11 11

10
10
Height, mm

Height, mm

9
9
8
8
7
7
6

6 5

5 4
0 0.5 1 1.5 2 2.5 3 0 0.5 1 1.5 2 2.5 3
Load, kg x 10
4 Load, kg 4
x 10

Figure.1 Change in height estimated by Fuzzy logic Figure.2 Change in height estimated by RBF

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13 38
Rbf
12 Fuzzy
36
Actual
11 Target
34
Estimated
Change in Height,mm

Buldge diameter, mm
10
32
9
30
8
28
7

6 26

5 24

4 22
0 0.5 1 1.5 2 2.5 3 0 0.5 1 1.5 2 2.5 3
Load, kg x 10
4
Load, Kg 4
x 10

Figure.3 Change in height estimated by RBF and Fuzzy logic Figure.4 Change in buldge diameter estimated by Fuzzy

38 38

36 36

34 34
Target
Buldge Diameter, mm

Buldge Diameter,mm Rbf

32 Estimated 32 Fuzzy
Actual
30 30

28 28

26 26

24 24

22 22
0 0.5 1 1.5 2 2.5 0 0.5 1 1.5 2 2.5 3
Load, kg x 10 Load, kg 4
x 10

Figure.5 Change in buldge diameter estimated by RBF

Figure.6 Change in buldge diameter estimated by RBF and Fuzzy logic

diameter. The performance of Fuzzy logic is superior REFERENCES

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