Influence of TiB2 particles on machinability and machining parameter optimization of TiB2/Al MMCs

In situ formed TiB2 particle reinforced aluminum matrix composites (TiB2/Al MMCs) have some extraordinary properties which make them be a promising material for high performance aero-engine blade. Due to the influence of TiB2 particles, the machinability is still a problem which restricts the application of TiB2/Al MMCs. In order to meet the industrial requirements, the influence of TiB2 particles on the machinability of TiB2/Al MMCs was investigated experimentally. Moreover, the optimal machining conditions for this kind of MMCs were investigated in this study. The major conclusions are: (1) the machining force of TiB2/Al MMCs is bigger than that of non-reinforced alloy and mainly controlled by feed rate; (2) the residual stress of TiB2/Al MMCs is compressive while that of non-reinforced alloy is nearly neutral; (3) the surface roughness of TiB2/Al MMCs is smaller than that of non-reinforced alloy under the same cutting speed, but reverse result was observed when the feed rate increased; (4) a multi-objective optimization model for surface roughness and material removal rate (MRR) was established, and a set of optimal parameter combinations of the machining was obtained. The results show a great difference from SiC particle reinforced MMCs and provide a useful guide for a better control of machining process of this material.