Optimization, error analysis and mathematical modelling of Al-SiCp metal matrix nano composites using coated carbide insert

Abstract

The present work deals with a challenging job for mixing of silicon carbide nano particles with aluminium metal matrix to form Al-SiCp nano composite using a ultrasonicator. Initially, Nano Indentation test of work material (Al-SiCp) has been carried out for 1, 1.5 and 2 wt% of SiCp nano particle and maximum hardness value of each sample was found out. It was observed that there was a proper dispersion of silicon carbide nano particles in the Al metal matrix. Machining Study of Al-SiCp metal matrix nano composite was conducted and the cutting forces were evaluated by using a strain gauge base lathe tool dynamometer. It was observed that all the three forces i.e. Feed force (Ff), Cutting Force (Fc) and Radial force (Fr) decreases by increasing the cutting speed at constant feed rate. Further, the design of experiment of Al-SiCp nano composite material using a coated carbide insert has been performed by Taguchi L16 orthogonal array at three different factors (feed, speed and depth of cut) at four different levels. The response parameters i.e. flank wear (VBc) of coated carbide tool and surface roughness (Ra) of work piece were evaluated and were optimized. The error analysis of both the responses were also analyzed. Finally, Quadratic Regression model of second order has been developed for both responses and the tool life was estimated.