Optimisation of machining parameters for minimising cutting forces during machining of Al alloy SiC particle composites

ABSTRACT

Machining experiments on 7075 Al alloy/10 wt% SiC (particle size 10–20 µm) have been conducted based on response surface methodology (RSM). Sequential approach using face-centred central composite design is followed. Optimum cutting speed is to be in the range 144-210, to have minimum tangential force, feed force  and radial force,, feed is to be in the range of 0.15–0.25 mm, depth of cut is to be 0.20 mm and nose radius 0.40 mm. Depth of cut is the leading contributor to the tangential force, whereas feed rate is the main contributor of the feed force. The quadratic model best describes the deviation of cutting force with main contribution of depth of cut and then contributions of interaction effect between feed and depth of cut, second-order (quadratic) effect of feed rate and interaction effect between speed and depth of cut. Suggested models of cutting forces sufficiently map within the limits of the cutting parameters. Optimum value parameters have been obtained at which cutting forces will be minimum and the performance and accuracy of machining will be improved.

KEYWORDS:

• Metal matrix composites (MMCs)
• tangential force
• feed force
• radial force
• optimisation

Disclosure statement

No potential conflict of interest was reported by the author.

Additional information

Notes on contributors

Rajesh Kumar Bhushan

Dr Rajesh Kumar Bhushan is currently working as Associate Professor in Department of Mechanical Engineering, Guru Ghasidas Vishwavidyalaya (A Central University) Bilaspur, Chhattisgarh, India. He has published 32 research papers in reputed international journals, 23 research papers in international conferences and 20 papers in national conferences. He has 23 years of experience in teaching, research and administration. He has completed 01 sponsored research project and 02 sponsored research project are under process. He is member of various international technical committee. He is PhD thesis examiner. He is certified energy manager and auditor by bureau of energy efficiency, ministry of power government of india.  He is reviewer of 25 reputed international journals. He has guided 03 PhD and 34 M Tech students so far. He has delivered 15 invited lectures at national/ international conference/workshop. His research interest  are fabrication, characterization and design  of composite structures, micro manufacturing and nano materials, applications of optimization techniques, artificial intelligence applications in manufacturing, high performance computational modelling of engineered systems and multi disciplinary design optimization.