Experimental Investigations to Study Tool Wear During Turning of Alumina Reinforced Aluminium Composite

Metal matrix compositions (MMC) have become a leading materials and particles reinforced aluminum MMCs have received considerable attention due to their excellent mechanical properties like high hardness, high tensile strength etc. These materials are difficult to machine because of high hardness and abrasive nature of reinforcing elements like alumina particles. In this study, homogenized (2%, 4%, and 6% by weight of alumina) aluminum metal matrix composite materials were fabricated and selected as workpiece for experimental investigations of tool wear, surface roughness and metal removal rate. The titanium nitride coated tungsten carbide tool and uncoated tungsten carbide tools were used at different cutting speeds (265,400,535 rpm), feed rates (0.29, 0.32, 0.35 mm/rev.), and depth of cut (1.0, 1.5, 2.0 mm). The microstructures and mechanical properties of produced composite specimens have been investigated. It has been observed that increase of reinforcement element produced better mechanical properties such as hardness and tensile strength. The turning experiments were planned by Taguchi method. The obtained experimental data has been analyzed using signal to noise ratio and ANOVA. The main effects have been discussed and percentage contribution of various process parameters speed, feed, depth of cut and concentration effecting tool wear, surface roughness and metal removal rate have been determined. Empirical relations by regression have been developed to predict the tool wear, surface roughness and material removal rate as a function of considered process parameters.