Modeling and optimization of Al/SiCp MMC machining using Taguchi approach

This paper presents the influence of process parameters like cutting speed, feed and depth of cut on flank wear (VBc) and surface roughness (Ra) in turning Al/SiCp metal matrix composites using uncoated tungsten carbide insert under dry environment. The experiments have been conducted based on Taguchi's L9 orthogonal array. Abrasion and adhesion are observed to be the principal wear mechanism from images of tool tip. No premature tool failure by chipping and fracturing was observed and machining was steady using carbide insert. Built-up-edge formation is noticed at low and higher cutting speed and at high feed combination and consequently surface quality affected adversely. The optimal parametric combination for flank wear and surface roughness are found to be v1-f1-d3 and v3-f1-d3 respectively and is greatly improved through Taguchi approach. Mathematical models for flank wear and surface roughness are found to be statistically significant.