Investigation on the optimal machining of Mg-based composites considering surface roughness, tool life, cutting forces, and productivity

Abstract

Machining of metal matrix composites (MMC) are being increasingly taken into consideration due to MMCs’ especial features like high strength to weight ratio, resistance to wear and creep. In this paper, effects of cutting parameters on the surface quality, tool life, and cutting force when machining of AZ91/SiC composites are analyzed to make the process optimized. To this end, a design of experiment based on the response surface methodology are done to consider variations of cutting parameters such as cutting speed, feed rate, and depth of cut. Challenges like particles pulled out and tool worn out in the machining process are evaluated. Subsequently, the results of cutting responses are analyzed and a multi-objective optimization is applied on the data to obtain the best surface quality, the highest production volume and the condition at which tool life is longest. The results showed although increasing the feed rate from 0.05 to 0.1 mm/rev leads to the tool life reduction about 70%, it enhances the productivity considerably about 100% for composites with volume fraction 5%. Moreover, at cutting speed 41.05 m/min and feed rate 0.07 mm/rev, machining process of AZ91/SiC-vol.5% becomes efficient.