Effects of Turning Parameters and Parametric Optimization of the Cutting Forces in Machining SiCp/Al 45 wt% Composite

Rashid Ali Laghari,Mozammel Mia,Jianguang Li

doi:10.3390/met10060840

Rashid Ali Laghari, Mozammel Mia + Show 1 more

Open Access

https://doi.org/10.3390/met10060840

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Journal: Metals	Publication Date: Jun 24, 2020
Citations: 38	License type: CC BY 4.0

Affiliation: Harbin Institute of Technology, Imperial College London

Abstract

Cutting force in the machining process of SiCp/Al particle reinforced metal matrix composite is affected by several factors. Obtaining an effective mathematical model for the cutting force is challenging. In that respect, the second-order model of cutting force has been established by response surface methodology (RSM) in this study, with different cutting parameters, such as cutting speed, feed rate, and depth of cut. The optimized mathematical model has been developed to analyze the effect of actual processing conditions on the generation of cutting force for the turning process of SiCp/Al composite. The results show that the predicted parameters by the RSM are in close agreement with experimental results with minimal error percentage. Quantitative evaluation by using analysis of variance (ANOVA), main effects plot, interactive effect, residual analysis, and optimization of cutting forces using the desirability function was performed. It has been found that the higher depth of cut, followed by feed rate, increases the cutting force. Higher cutting speed shows a positive response by reducing the cutting force. The predicted and experimental results for the model of SiCp/Al components have been compared to the cutting force of SiCp/Al 45 wt%—the error has been found low showing a good agreement.

Highlights

Metal matrix composites (MMCs) are a kind of composite materials, which is one of the pioneers of the modern key industrial heavy-duty parts and products for nearly 30 years
The signs that hinder the wider applications of the MMCs in the industrial sector, include serious tool wear, bad surface quality, issues related to the dimensional accuracy of component, etc. [5,6]
The experimental research work of this paper investigates the influence of machining parameters on the cutting force in turning process of difficult-to-cut hard material SiCp/Al reinforced metal matrix composites

Summary

Introduction

Metal matrix composites (MMCs) are a kind of composite materials, which is one of the pioneers of the modern key industrial heavy-duty parts and products for nearly 30 years. Aluminum metal matrix composite materials have wide application prospects in transportation, aviation, aerospace, medical industries, including many other important areas of different structural applications [3,4]. The researchers put more efforts in sorting out such kind of hindrances—different kinds of cutting tool material were introduced along with suitable machining operations to fulfill the gap. Such types of tools include polycrystalline diamond

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