Investigation on the effects of machining performances for milling Al-30%/SiC-70% infiltrate metal matrix composites

Abstract

The unique properties of Al-30%/SiC-70% Metal Matrix Composite (MMC) such as lightweight, high strength, and wear resistance has made it as an alternative material for precision machinery parts. Owing to the presence of hard-abrasive reinforcement particles within the matrix, these materials are known as low machinability rating materials. Furthermore, the absence of a dedicated cutting tool for machining MMC materials is the cause of many intrinsic issues., such as high surface roughness and high cutting temperature. In this work, the application of the Taguchi method to determine the effect of the cutter geometric characteristics and cutting parameters for Al/SiC MMC machining is perform. During the planned experiment, sixes parameters were taking into consideration namely helix angles, rake angles, clearance angles, number of flutes, spindle speed, feed rates and depth of cut. The measured responses are surface roughness and cutting force, which is important for the functionality of the component. ANOVA was used to validate each factor's percentage contribution. The results show that the main factor contributing to fine surface roughness and low cutting force is fewer flutes. Fewer flutes give a smooth chip executable flow, minimizing the friction of the cutting area vital in composites materials such as MMC. Because they provide optimum sheared power, helix angles, spindle speed, and cutting depth also influence the mechanical performance. The clearance angle of both reactions is found to be less important since it only controls the damping process and stability. The main conclusion is that the cutter geometric characteristics and cutting parameters are significantly affected by machining performance and therefore the need for special design cutters is concluded for the efficient production of Al/SiC MMC materials.