Optimization of Machining Parameters for Surface Roughness and Burr Height in Drilling Hybrid Composites

Abstract

This article focuses on the multiple performance analysis in machining characteristics of drilling hybrid metal matrix composites produced through stir casting route. The desirability function-based approach is employed for the optimization of drilling parameters, namely, spindle speed, feed rate, and wt% of SiC based on the multiple performance characteristics including surface roughness and burr height. Material used for the present investigation is Al 356-aluminum alloy reinforced with silicon carbide of size 25 microns and mica of an average size of 45 microns. Experiments are conducted on a vertical machining center using the Box--Behnken experimental design (BBD) technique. The drilling test is carried out using coated carbide drill of 6 mm diameter. An empirical model has been developed for predicting the surface roughness and burr height in drilling of Al 356/SiC-mica composites. The optimization results showed that the combination of medium spindle speed, low feed rate, and high wt% of SiC is necessary to minimize burr height and surface roughness in drilling hybrid composites.