Surface roughness and tool wear analysis while turning Al/SiCp metal matrix composites

Abstract

Al/SiCp is special types of metal matrixes composite which shows excellent mechanical properties and have wide range of application. This paper represents optimum process parameters on Al/SiCp metal matrix composites. For experimental investigation 2024-Al alloy has been used as matrix material and reinforcement as silicon carbide powder (SiCp). A stir casting process was used to developed Al/SiCp metal matrix composite in which 20% weight fraction of SiCp reinforcement has been chosen having 220 mesh size (65µm). The experiment involves turning operation in which cutting tool used as carbide insert having TiN coating. The three process parameter with three levels is considered for experimentation i.e. speed 150 to 250 m/min, feed rate 0.05 to 0.1 mm/rev and DOC 0.5 to 1 mm are under dry state condition. Taguchi L9 orthogonal array methodology was done to decide the optimum process parameter using SN ratio. To identify machinability of Al/SiCp MMC study focused on surface roughness and tool wear response variables. The experimental study showed that the speed is the utmost substantial factor as compared to DOC and feed in case of surface roughness while for tool wear the speed is the most important factor than feed rate and DOC. The signal-to-noise ratio gives optimum conditions as speed of 200 m/min, the feed 0.07 mm/rev, and DOC 0.5 mm for the surface roughness and for tool wear optimum conditions as speed of 150 m/min, the feed 0.07 mm/rev, and DOC 0.75 mm.