Advances in machine technology and improvements in Al-SiCp nano composite materials by using multi-layer coated carbide tool

Abstract

The current research paper deals with the advancement of metal matrix aluminium (Al) material and reinforcement of silicon carbide (SiCp) nano material to form (Al-SiCp) nano composite. The fabrication process was completed by mixing of 1, 1.5 and 2 wt% of Silicon carbide with liquid aluminium metal. From the experimental study, it was observed that 2 wt% of SiCp when mixed with aluminium metal matrix gives the best sample results for Al-SiCp nano composite as well as it is suitable for machining process. In the current work, the machining of nano composite was carried out by using CNC lathe with multilayer coated carbide cutting insert. Three process parameters i.e. feed, depth of cut and speed at four various levels was experimentally varied by using Taguchi L 16 orthogonal array. Principal component Analysis (PCA) was used to optimized the output parameters of surface roughness of the work piece material and the tool flank wear. The optical microscopy study was conducted to find out the heat affected zone and wear of the cutting tool. Analysis of Variance (ANOVA) was also applied to determine the most influencing parameter affecting the Multiple Performance Index (MPI). Different plots like main effect plot, interaction plot, surface plot, contour plot, normal probability plot and distribution fit plot were analyzed to confirm the stability of the model.