Improving productivity through maximizing MRR in machining silicon nitride ceramic reinforced aluminium alloy 5052

Abstract

The research is to improve the material removal rate (MRR) during machining the novel silicon nitride (Si3N4) reinforced AA5052 aluminium matrix composite (AMMC) and comparing the MRR obtained with as cast AA5052. The present research work focuses on the fabrication of novel AA5052 matrix composite reinforced with Si3N4 by conventional stir casting method. For machining investigation two groups are considered; experimental group (AA5052 + 9 %Si3N4) and control group (as cast AA5052). For each group 27 samples were considered based on the sample size calculator. Addition of Si3N4 improves mechanical strength and thereby reduces the MRR. Higher MRR is obtained during machining as cast AA5052 than the novel AA5052 + 9 %Si3N4 due to non-inclusion of ceramic particulates. The mean value of MRR obtained for as cast AA5052 is 1.1074 g/min and for AA5052 + 9 % Si3N4 is 0.7367 g/min. The significance value obtained from independent sample T-test is 0.002 which is lower than the desired p < 0.05. Conclusion: Within the limits of this study, achieving a higher material removal rate is desired as it increases the production rate along with optimal conditions. But with inclusion of hard reinforcements in the soft matrix, machinability tends to be lower and hence less MRR is observed for the experimental group when compared with the control group.