Analysis of Tool Wear while Milling Hybrid Metal Matrix Composites

Abstract

In the present work, an attempt has been made to analyze the factors influencing tool wear while milling Al/Al2O3/Gr particulate composites. Materials used for the present investigation are Al 6061-aluminium alloy reinforced with alumina (Al2O3) of size 45 microns and graphite (Gr) of an average size 60 microns, which are produced by stir casting route. Central composite design (CCD) was employed in developing the tool wear model in relation to machining parameters such as feed rate, cutting speed, depth of cut and weight fraction of Alumina. From the Analysis of variance (ANOVA), it is found that feed is the dominant parameter for tool wear whereas weight fraction of alumina shows minimal effect on tool wear compared to other parameters. From the Scanning Electron Microscope (SEM), the Al2O3 and Gr particles get adhered to the tool surface owing to the high pressure generated at the tool-workpiece interface.