Analysis of Al-SiCp nano composite and study of its machining process by using coated carbide tool

Abstract

The present study deals with aluminium and silicon carbide (Al-SiCp) metal matrix nano composite material. In this process, silicon carbide nano particles of weight fraction 1%, 1.5% and 2% weight are mixed with aluminium molten metal. Optical microscopy study is conducted for all the samples and it is found that there is some formation of minute cracks only for 2 wt% sample which might be due to the generation of high heat and temperature. Later, the machining of Al-SiCp workpiece has been carried out by CNC lathe using coated carbide insert. The design of experiment has been obtained by Taguchi L16 orthogonal array at three different factors (feed, speed and depth of cut) at four different levels. The response parameters i.e. flank wear of coated carbide tool and surface roughness of the Al-SiCp workpiece has been optimized by using Principal Component Analysis. After the machining operation, heat affected zone, tool wear, burr and damaged zone of the tool can be observed under Scanning Electron Microscope. Analysis of Variance confirms feed, depth of cut and cutting speed to be the most significant parameters affecting the Multiple Performance Index.