Optimization of cutting force and surface roughness in end milling of AA-TiCp composite

Abstract

Nowadays Aluminium alloy (AA) based composites are used in many fields such as automotive, aerospace, electronics, and marine industries. But for the utilization of these composites for different applications with different shapes, machining especially end milling is the essential process. Hence, this work describes the optimization of surface roughness and cutting forces during end milling of A356 aluminium alloy reinforced with titanium carbide particle (TiCp) metal matrix composites (MMCs). A356 alloy with 0, 3 and 6 vol% of TiCp (average size of 50 µm) composites were prepared using a stir casting process. The effects of milling process factors, namely cutting speed, feed, depth of cut, and volume % of TiCp, on average surface roughness (Ra) and cutting forces have been studied using a Box-Behnken design of the experiment technique. The end milling experiments were performed in a CNC vertical machining center without any cutting fluid using uncoated cemented carbide inserts. Using Design Ease software, the predictive model analysis and change in performance measurements for process variables were provided. The results showed that the depth of cut, followed by cutting speed, is the most important criterion and finally optimal levels of process variables were also identified to improve the machinability of the composites.