Turning Parameters Optimizing for Surface Quality of Al- MMCs: A Comparative Study of Cutting Environments

Abstract

Abstract The machining of Aluminum-based Metal Matrix Composites (Al-MMCs) is challenging due to their inhomogeneity, anisotropic nature, and dynamic cutting forces. In this paper, the effect of machining parameters, including cutting speed, feed rate, and depth of cut, on surface quality (Ra) and cutting forces (Fc) during turning of Al-MMCs under different cutting conditions (DRY, WET, and MQL) was investigated. Statistical analysis tools were used to analyze the experimental results, and ANOVA and RSM techniques were used to model the relationships between machining parameters and responses. The results showed that feed rate had the most significant effect on both Ra and Fc for all machining conditions. The optimum feed rate of 0.03 mm/rev was found to produce the best surface finish and lower cutting forces in all conditions. The DRY mode of machining was found to be optimal for surface finish, and the MQL mode was found to be effective in reducing cutting forces due to its cooling and lubrication properties. Future research should focus on investigating the effect of different cutting tool materials and geometries on the machinability of Al-MMCs and developing more effective and sustainable machining strategies.