Experimental Investigation and Optimization of Cutting Force and Tool Wear in Milling Al7075 and Open-Cell SiC Foam Composite

Abstract

In the present study, aluminium alloy-based metal matrix composites were fabricated by infiltrating Al7075 into a three-dimensional open-cell silicon carbide (SiC) foam using the liquid metallurgy method. The effects of machining variables on the milling force and tool wear during milling of both Al7075 and the open-cell SiC foam metal matrix composite (MMC) using an uncoated carbide cutting tool were studied. The milling experiments were performed based on the Taguchi $${{\rm L}_{27}}$$ full-factorial orthogonal array, and the milling variables were optimized for cutting force and tool wear. The test results showed that the cutting depth was the most significant cutting parameter affecting milling force in the milling of both workpiece materials. Cutting tool wear was directly affected by the cutting depth in the milling of MMC, and the feed rate was the most influential factor on the tool wear in the milling of Al7075. Uncoated carbide tool showed an excellent machining performance below a machining speed of 220 m/min in finish milling Al7075 workpiece material, but excessive edge chipping was observed on the cutting tool surface in the milling of MMCs. Second-order mathematical models with respect to milling parameters were created for prediction of cutting force and tool wear.