A Study on Process Parameters in Milling of Al-MMC

Abstract

Metal Matrix Composites have become a leading material among composite materials. In particular, particle reinforced Aluminum Metal Matrix Composite (AMMC) have received considerable attention due to their excellent engineering properties. Aluminum metal matrix refers to the class of light weight high performance aluminum centric material systems. The reinforcement in AMC’s could be in the form of   continuous/  discontinuous  fibers,  whiskers  or Particulates in volume fractions ranging in percentages. Properties of AMC’s can be tailored to the demands of different industrial applications by suitable combinations of matrix reinforcement and processing routes.

In this study an attempt has been made to manufacture the AMC through a liquid metallurgical route. The matrix used in the study is Aluminum alloy and reinforcement particles selected are Silicon Carbide (SiC) particles ranging its size from 50-70 microns. The study also focuses to establish a mathematical relationship between process parameters like Cutting speed, Feed Rate, Depth of cut and surface roughness (Ra) in End Milling operation. A CNC machining center with 8 mm diameter HSS end milling cutter with 30° helix angle is used for machining by employing a L16 (44) Taguchi’s orthogonal array for the experiment plan. A linear and multiple regression analysis using analysis of variance is  conducted to determine the performance of experimental measurements and to show the effect of four cutting parameters on the surface roughness.RSM methodology  was selected to optimize the surface roughness resulting minimum values of surface roughness and their  respective optimal condition.