Experimental Investigation and Optimization of Cutting Force and Tool Wear in Milling Al7075 and Open-Cell SiC Foam Composite

KARABULUT Ş., Cinici H., KARAKOÇ H.

ARABIAN JOURNAL FOR SCIENCE AND ENGINEERING, cilt.41, sa.5, ss.1797-1812, 2016 (SCI-Expanded) identifier identifier

  • Yayın Türü: Makale / Tam Makale
  • Cilt numarası: 41 Sayı: 5
  • Basım Tarihi: 2016
  • Doi Numarası: 10.1007/s13369-015-1991-4
  • Dergi Adı: ARABIAN JOURNAL FOR SCIENCE AND ENGINEERING
  • Derginin Tarandığı İndeksler: Science Citation Index Expanded (SCI-EXPANDED), Scopus
  • Sayfa Sayıları: ss.1797-1812
  • Anahtar Kelimeler: Al7075, Open-cell SiC foams, Cutting force, Tool wear, Taguchi method, Response surface methodology, RESPONSE-SURFACE METHODOLOGY, METAL-MATRIX COMPOSITES, MACHINING PARAMETERS, AL/SIC-MMC, FLANK WEAR, ROUGHNESS, MACHINABILITY, MODEL
  • Hacettepe Üniversitesi Adresli: Evet

Özet

In the present study, aluminium alloy-based metal matrix composites were fabricated by infiltrating Al7075 into a three-dimensional open-cell silicon carbide (SiC) foam using the liquid metallurgy method. The effects of machining variables on the milling force and tool wear during milling of both Al7075 and the open-cell SiC foam metal matrix composite (MMC) using an uncoated carbide cutting tool were studied. The milling experiments were performed based on the Taguchi L27 full-factorial orthogonal array, and the milling variables were optimized for cutting force and tool wear. The test results showed that the cutting depth was the most significant cutting parameter affecting milling force in the milling of both workpiece materials. Cutting tool wear was directly affected by the cutting depth in the milling of MMC, and the feed rate was the most influential factor on the tool wear in the milling of Al7075. Uncoated carbide tool showed an excellent machining performance below a machining speed of 220 m/min in finish milling Al7075 workpiece material, but excessive edge chipping was observed on the cutting tool surface in the milling of MMCs. Second-order mathematical models with respect to milling parameters were created for prediction of cutting force and tool wear.