Abstract
Hard Si particles when dispersed widely throughout a eutectic α-Al matrix forms hypereutectic Al-Si binary alloy which is actually a simple in situ metal matrix composite (MMC). Hence, like other Al MMCs, they offer amalgamation of high strength-to-weight ratio and excellent wear resistance properties with high specific elastic modulus, exceptional heat-resistance and low thermal expansion and hence, are used in many industries. Machining of such materials like all other Al alloys is a challenging task mostly because of formation of built-up edges (BUEs) and long continuous chips. A case study of machinability evaluation of such a hypereutectic material with excess Si contents manufactured by gravity cast is presented. The study has been accomplished through investigation and analysis while carrying out turning experiments on a lathe by coated carbide tool inserts. The Taguchi orthogonal array is used for design and Response Surface Methodology has been employed for regression analysis and optimization.
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