Experimental Analysis and Forecasting of Material Removal Rate and Cutting Force in End Milling on A356 Alloy-SiC Metal Matrix Composites

Abstract:

By considering several applications of aluminum based particle reinforced composites especially in automobile, aerospace and electronic industries, in this work, prediction of machinability responses of A356 alloy-SiC particles (5, 10, 15 and 20 vol%) reinforced metal matrix composites is described. Composites were synthesized by vacuum hot pressing (VHP) assisted powder metallurgy (P/M) process. Effect of cutting speed (Vc), feed (f), depth of cut (d) and quantity of SiC (vol %) on machinability of composites in terms of material removal rate (MRR) and resultant cutting forces (F_R) during end milling were investigated. Milling experiments were carried in dry condition based on central composite design and KISTLER dynamometer was used to measure cutting forces. Resultant cutting force values were increased from 21 to 105 N with an increase in ‘f’ and ‘d’, but decreased with increase in ‘Vc’. Increase in machining parameters increased the MRR from 2.3 to 8.6 × 10³ mm³/min and increase in SiC reduced the MRR. Statistical modeling with cubic response equations were used to predict the results and predicted results were closely matching with experimental values.

• Periodical: Applied Mechanics and Materials (Volume 787)
• Pages: 637-642
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.787.637
• Online since: August 2015
• Authors: K. Jayakumar*, Jose Mathew, M.A. Joseph
• Keywords: A356 Alloy-SiC Metal Matrix Composites, Cutting Force, End Milling, MRR, Statistical Modeling, Vacuum Hot Pressing Technique

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