Investigating the machinability behaviour of Al7075/SiC5CS5 hybrid composite with the variation of tool geometry

Abstract

This research investigates the machinability behavior of an Al7075 hybrid composite fabricated with micro-sized cenosphere (CS) and silicon carbide (SiC) particles. The composite was fabricated using stir-casting with ultrasonic assistance. The experimental study investigated the effect of variation of machining regimes (i.e., feed rate, cutting speed, and depth of cut) and tool geometry (tool nose radii) on main cutting force and tool tip temperature. For the study, the Cermet tool was considered as tool material for the dry turning of aluminum alloy and composite. In addition, a regression model was created using the response surface method (RSM) technique. The results indicate that the developed model can accurately predict output regimes with an accuracy ranging from 80.44 to 99.98%. Further, by using sequential approximation optimization, the optimal combination of input regimes for maximal metal removal rate was identified.