Comparison of Machinability of Al-4.5%Cu/TiB2/3p MMC for Multi-Layer Coated Insert: Validated FEM and Statistical Approaches

Abstract

Aluminum-based Metal Matrix Composites (MMC) are commonly used in metal-cutting applications due to their better mechanical and physical properties, such as high strength, hardness, and low weight. Also, modern coating applications, especially multi-layer coated tools, have the cutting-edge potential for relieving the difficulties of machining MMCs to improve insert performances. Therefore, this study aimed to reveal the turning Al-4.5%Cu/TiB2/3p performance of the multi-layer coated cemented carbide insert with verified FEM and statistical approaches. Different coating materials, two and three of which were soft and hard, were appointed at different thicknesses and sequences in the design of experimentally calibrated simulations. The Grey Relation Analysis (GRA) was set to investigate the multi-layer coated insert performance for turning the MMC concerning the resultant cutting forces (FR) and maximum insert temperature (Tmax). The optimal multi-layered coating was found at levels 4-2-4-3-2 for the factors of coating materials: tungsten disulfide (WS2), molybdenum disulfide (MoS2), titanium nitride (TiN), aluminum oxide (Al2O3), and titanium carbo-nitride (TiCN), respectively. The contribution rates of each factor were significant concerning General Linear Model (GLM) at 47.13% and 24.43% for WS2 and Al2O3 coatings materials, respectively. In the future, multi-layered coatings can be a valuable solution for the difficulties of machining the MMCs.