Abstract
Aluminum and its alloys have numerous applications in manufacturing, aerospace, and automotive industries. At elevated temperatures, they start to fail in fulfilling their roles and functions. Aluminum-based metal matrix composites (MMCs) are good alternatives for metal and alloys due to their excellent properties. However, the conventional machining of several composites shows complications for a number of reasons, such as high tool wear, poor surface roughness, high machining cost, cutting forces, etc. Numerous studies have already been conducted on the machinability of various MMCs, but the machinability of Al–Si–TiB2 composite is still not well studied. It is of utmost importance that several process parameters of conventional machining are precisely controlled as well as optimized. In this study an effort was made to optimize input parameters such as cutting speed, depth of cut, and feed to obtain well-finished final components with the minimum cutting force and tool wear. These progressions are involved with multiple response characteristics, therefore the exploration of an appropriate multi-objective optimization technique was indeed essential. The performance characteristics of cutting forces and surface roughness were considered for optimization of the machining parameters. Analysis of variance (ANOVA) was employed for the optimization and statistical analysis.
Highlights
The demand for aluminum–silicon alloy-based composites is rapidly increasing in automobile and aerospace sectors
From past machining studies conducted on Al–SiC composites, it was observed that tool wear was extreme, and the surface finish was poor with carbide tool inserts
Polycrystalline diamond (PCD) insert performance was found to be pointedly much better than the carbide tool inserts during the turning of Al/5%Mg alloys reinforced with 5 wt.% saffil and 15 wt.% SiCp [5,6]
Summary
The demand for aluminum–silicon alloy-based composites is rapidly increasing in automobile and aerospace sectors. The durability of the cutting tools is one of the major indicators of the efficiency of a machining process, as the overall cost of the machining majorly depends on the life cycle and cost of cutting tools [4] While in another observation, polycrystalline diamond (PCD) insert performance was found to be pointedly much better than the carbide tool inserts during the turning of Al/5%Mg alloys reinforced with 5 wt.% saffil and 15 wt.% SiCp [5,6]. Most of the studies widely report on tool wear performance during the machining of MMCs based on Al–SiC or Al2O3 processed using conventional casting methods. Studies have been conducted on the optimization of output parameters like surface roughness and cutting force for turning operation of AlB2/Al–Mg3 MMCs. A statistical method was employed for optimizing the process parameters.
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