OPTIMIZATION OF MACHINING PARAMETERS IN

MILLING OPERATION OF HYBRID METAL

MATRIX COMPOSITES (Al7075/SiC+B4C)
Ramesh C1, S. Balamurugan2, R. Kuhapriyan2, M. Aravindhan 2
1,2
Department of Mechanical Engineering, K.S.Rangasamy College of Technology, Tiruchengode, Namakkal,
Tamil Nadu 637215, India

base material.
AB STRACT
This paper deals with the fabrication of aluminium Aluminium metal matrix complex are known as the hard-to-
alloy 7075 with Silicon Carbide and Boron Carbide to form a machine materials considering the hardness and abrasive nature
hybrid metal matrix composite. Here Aluminium is the of reinforcement element like alumina Al2O3 particle. [7] Poor
Matrix and Silicon Carbide and Boron Carbide are used as surface finish and vibration are the mostly faced problems during
Reinforcement. The fabrication is done by using Stir Casting milling of the metals. Damage on the metals is possible during
method. After solidification Machining process takes place in end milling at non optimized parameters which may affect the
the specimen. Then machining parameters like Speed, Depth quality of final products. Flank wear during milling was found
of cut and Feed rate are used to identify the Surface roughness to considerably increase the thermal load of the workpiece [7].
of the specimen. Surface roughness was measured by using [8] Milling is the machining process of using rotary cutters to
column type surface roughness tester (Mitutoyo Surf test SV- remove material from a workpiece by advancing (or feeding) in
2100). Optimal parameters are found by taguchi method a direction at an angle with the axis of the tool. It covers a wide
using minitab software. ANOVA (Analysis of Variance) variation of different operations and machines, on scales from
technique is used to find which parameter influences the most small specific parts to large, heavy-duty gang milling operations.
in machining hybrid aluminium specimen. It is one of the most commonly used processes in industry and
machine shops today for machining parts to accurate sizes and
1. I N T R O D U C T I O N shapes. Firstly the parameters which causes the surface roughness
were studied from the literature. Generally the parameters
MMC (Metal matrix composites) are metals fortified influencing milling are cutting speed, feed rate and depth of cut
with other metal, ceramic or organic compounds. They are put compared to other parameters. The parameters level are fixed
together by scattering the reinforcements in the metal matrix. from 1000 – 3000, 0.1 – 0.3, 0.1 – 0.3 for cutting speed, feed rate
Reinforcements are usually done to improve the characteristics and depth of cut [8].
of the base metal like strength, stiffness, conductivity, etc.
Aluminium and its blend have fascinated most observation as The specimens of aluminium hybrid metal were machined in
base metal in metal matrix composites. [10] Aluminium MMCs CNC mill. [9] The surface roughness is measured by Mitutoyo
are widely used in aircraft, aerospace, automobiles and various Surf test SV-2100 column-type surface roughness tester with its
other fields. Aluminum-7075 series alloys frequently used in specifications of a measuring range of 5 mm, and measuring
transportation implementation are aerospace, aviation, marine speed of 0.25-0.5mm/s. The surface roughness is measured by
and automobile due to their good mechanical characteristics positioning the stylus perpendicular to the feed marks on the
and low density and high strength-to-density ratio. The machined surface towards the end of cutting. The results were
reinforcements should be durable in the given working obtained using the Mitutoyo software [9]. Finally the results
temperature and non-reactive too. The most frequently used obtained were analyzed using the origin software and the results
reinforcements are Silicon Carbide (SiC). SiC reinforcement obtained controversial to the studies in literature were corrected
improves the tensile strength, hardness, density and wear by trial and error method. Then using the results the parameters
resistance of Al and its alloys. The particle diffusion plays a very are optimized and the optimized parameters are found using the
vital role in the characteristics of the Al MMC and is enhanced minitab software. In the report analysis, the reports obtained were
by intensive shearing [10]. Boron Carbide is one of hardest analysed by repeating the experiments.
investigated elements. It contains high elastic modulus and
fracture toughness. The addition of Boron Carbide (B4C) in Al 2. E X P E R I M E N T A L S E T U P
matrix improves the hardness.
2.1 COMPOSITION OF ALUMINIUM METAL
Stir casting is an inexpensive process for the MATRIX COMPOSITE
fabrication of aluminium matrix composites. The stir casting
procedure were used for the making of AMMCs, which is most 2.1.1 Matrix Material (Aluminium 7075 Rod)
simplest and inexpensive process for particulate reinforced
metal matrix composites. Optimum characteristic of the hybrid Aluminium 7075 alloy is used as the matrix material. The
composites were acquired by proper distribution of particulate required quantity of aluminium 7075 alloy is purchased in the
reinforcement in the base material. The stirrer is used to acquire form of rods. Figure 2.1 shows the as-received aluminium alloy.
a high-quality distribution of the reinforcement material in the
The chemical composition, physical, and Mechanical properties Boron carbide gives outstanding resistance to abrasive wear. It
of the aluminium 7075 alloy are given in Tables 2.1 and 2.2. tends to contain second-phase graphite and it is this property
which has a major influence on the strength of the material.It has
the properties of low thermal conductivity, outstanding
hardness and extremely brittle.

Figure 2.1 Aluminium 7075 rod

Table 2.1 Chemical composition of Al-7075 alloy

Element Wt (%)
Figure 2.3 Boron carbide particles
Cr 0.18-0.28
Cu 1.2-2 Both can be used as abrasives. Silicon Carbide also has good
Fe 0.5 mechanical properties like low density, high strength, low
Mg 2.1-2.9 thermal expansion, high thermal conductivity etc. Silicon
Mn 0.3 carbide applications are used in seals, bearings, ball valve parts,
Si 0.4 heat exchangers,semiconductors etc. Boron carbide has good
Ti 0.2 mechanical parameters like high hardness, highmelting point,
Zn 5.1-6.1 low specific weight, chemical resistance etc. Boron carbide is
Al Remaining used in nuclear applications like shielding, control rods and shut
down pellets.
Table 2.2 Physical and mechanical properties of Al-7075
2.2 MANUFACTURING OF ALUMINIUM
SI. No Properties Value
METAL MATRIX COMPOSITE
1 Density (g/cc) 2.81
Ultimate Tensile
2 573
Strength (MPa) Stir casting method was used to manufacture the
Tensile Yield aluminum metal matrix composites. The stirrer is employed to
3 503
Strength (MPa) get a high-quality distribution of the reinforcement material in the
Modulus of base material. Aluminium alloy was melted in the furnace at a
4 71.7
Elasticity (GPa) temperature range of 600–800 ◦C. A stirrer is used in the molten
5 Poisson’s ratio 0.33 metal and revolved at 200–600 rpm by electric motor for about
Brinell Hardness 10–20 min so that a whirlwind is created. Preheated particle
6 150
Number reinforcement subsequently introduced at the region of the vortex
to obtain uniform distribution of particle materials in base matrix.
2.1.2 Reinforcement Material SiC and Boron Carbide particles were used as reinforcement to
fabricate Al - 3 wt% SiC and Boron Carbide composites at two
Silicon carbide and boron carbide are used as reinforcement casting temperatures (680 and 850 degree celsius) and stirring
materials. The most important aspect of Aluminum-silicon periods (2 and 10 min). The weighted quantity of Aluminium
carbide with reference to the aerospace manufactures is its 7075 rods were added into the electrical furnace andheated up
strength to weight ratio, which is three times greater than mild to 700°C. After attaining the peak temperature, it gets started
steel. Composites containing SiC and Al have high modulus, melting in the furnace. In this project, reinforcement were added
strength values, wear resistance, high thermal stability, less on three different compositions. They are
weight and a more effective load carrying capacity.
 Aluminium with 1% SiC + 1% B4C

 Aluminium with 2% SiC + 2% B4C

 Aluminium with 3% SiC + 3% B4C

When the aluminum was fully melted, the required quantity of

powder mixture was added to it. For the proper mixing of
Figure 2.2 Silicon Carbide particles reinforcement with Aluminum, molten composite gets stirred
using stirrer which was connected to the motor. And then, it manufacturer. Three process parameters at three levels lead to a
gets poured into the mould which is in the rod shape. total of 27 tests forthe milling process by Taguchi method. A
constant cutting length of 38 mm for the work piece for the
milling was maintained for each experiment. The standard
orthogonal array L27 is chosen, which has 27 rows
corresponding to the number of parameter combinations [4].
The specimen after the milling process done is shown in the
Figure 2.8

Figure 2.4 Pouring of molten metal into mould

After solidification the casts are taken out from the mould. The
stir casted specimen is shown in Figure2.6

Figure 2.7 Experimental Setup

The figure shown below is a specimen after the completion of
milling. The milling doneon the specimens is end milling. The
end milling is carried out by taking passes on the specimens.
Each pass done on a specimen has a different combination over
another.
Figure 2.5 Stir cast specimen

2.3 MACHINING OF METAL MATRIX

COMPOSITES
Face milling operation is done on casted specimens
using conventional lathe to get the uniform cross section of
38mm and 27mm. Then the specimens was cut equally into
two bars. The machining operations are carried out on a
Figure 2.8 Milled specimen
Jobber XL CNC mill. The cutting tool used for the
experimentation is carbide end mill cutter. The ranges of the
feed and depth of cut are selected, based on the 2.4 SURFACE ROUGHNESS MEASUREMENT
recommendations given by the tool manufacturer. The
Sandvik PCLNR 20x20 cutting tool holder is used for the The surface roughness Ra is measured by Mitutoyo
experimentation. Figure 2.6 shows the type ofcutting tool used Surf test SV-2100 column-type surface roughness tester with its
for the experimentation. A cutting fluid is not used during the specifications of a measuring range of 5 mm, and measuring
machining process. Figure 2.7 shows the experimental setup speed of 0.25-0.5mm/s. The surface roughness is measured by
of milling positioning the stylus perpendicular to the feed marks on the
machined surface towards the end of cutting. The surface
roughness measuring in the turned specimen is shown in the
figure 2.9. The results of the surfaceroughness measurements are
shown in table 2.4.

Figure 2.6 Carbide tool

[4] In this study, three levels are specified for each process
Figure 2.10 Surface roughness test
parameter, as given Table 2.3. The parameter levels are picked
within the intervals, based on the guidance by the cutting tool
Table 2.3 Factor and Levels

Level
Parameters Unit
1 2 3

Cutting Speed RPM 1000 2000 3000

Feed Rate mm/rev 0.1 0.2 0.3

Depth of Cut Mm 0.1 0.2 0.3

Table 2.4 Results of Surface Roughness Test

Cutting speed Feed rate Depth of Surface roughness Ra (µm)

S. No cut

(rpm) (mm/rev) (mm) Al Al (2%) Al (4%) Al (6%)

1 1000 0.1 0.1 0.358 0.618 0.982 0.556
2 1000 0.1 0.2 0.277 0.716 0.693 0.536
3 1000 0.1 0.3 0.293 0.733 0.489 0.536
4 1000 0.2 0.1 0.608 0.76 1.252 0.963
5 1000 0.2 0.2 0.741 0.838 0.85 0.836
6 1000 0.2 0.3 0.964 0.85 0.81 0.736
7 1000 0.3 0.1 1.862 1.9 2.188 1.261
8 1000 0.3 0.2 0.81 2.302 1.075 1.812
9 1000 0.3 0.3 2.027 1.163 1.007 0.936

10 2000 0.1 0.1 0.554 0.246 0.788 0.483

11 2000 0.1 0.2 0.732 0.736 0.625 0.327
12 2000 0.1 0.3 0.503 0.68 0.607 0.39
13 2000 0.2 0.1 0.993 0.512 1.028 0.979
14 2000 0.2 0.2 0.873 1.159 0.76 0.882

15 2000 0.2 0.3 0.868 1.07 0.75 0.771

16 2000 0.3 0.1 1.103 1.12 2.5 1.21

17 2000 0.3 0.2 1.17 1.45 0.939 1.143

18 2000 0.3 0.3 1.702 1 1.005 1.11
19 3000 0.1 0.1 0.408 0.762 0.278 0.517

20 3000 0.1 0.2 0.241 0.467 0.299 0.633

21 3000 0.1 0.3 0.36 0.27 0.39 0.431
22 3000 0.2 0.1 0.966 0.543 0.673 1.312
23 3000 0.2 0.2 0.922 1.647 0.365 0.752
24 3000 0.2 0.3 1.25 0.756 1.019 0.836

25 3000 0.3 0.1 2.342 1.332 1.392 1.595

26 3000 0.3 0.2 1.429 2.095 2.084 0.952

27 3000 0.3 0.3 1.466 1.361 1.768 1.14

3. R E S U L T S A N D D I S C U S S I O N S

3.1 OPTIMIZATION OF MACHINING CONDITIONS The aim of this study is to determine the optimum conditions for
USING THE TAGUCHI METHOD
cutting Al (2%SiC/B4C)using three types of cutting parameters.
One of the methods used to analyse data for process optimization
uses SN ratio. Fig.3.2 (a) shows the mean of SN ratio for larger-
the-better characteristics of tool life obtained using Minitab 15.
The slope of the graphs clearly shows that the feed rate is the most
significant factor, followed by the type of and cutting speed and
depth of cut. Based on Fig.3.2 (a), the optimum machining
parameters for cutting Al are found at thelevel where each factor
has the largest S/N ratio. Therefore, the optimal machining
conditions for tool life were found to be the cutting speed of
2000rpm, feed rate of 0.1 mm/rev, depth of cut of 0.1 mm. This
is supported by the results of the sensitivity graph of the mean
cutting condition as shown in Fig. 3.2 (b).

Figure 3.1 (a) S/N ratios graphs of response for

aluminium; (b) Main effects plot for means for aluminium

The aim of this study [2] is to determine the optimum conditions

for cutting Al using threetypes of cutting parameters. One of the
methods used to analyse data for process optimization uses SN
ratio. Fig.3.1 (a) shows the mean of SN ratio for larger-the-better
characteristics of tool life obtained using Minitab 15. The slope
of the graphs clearly shows that the feed rate is the most
significant factor, followed by the type of cutting speed and
depth of cut. Based on Fig.3.1 (a), the optimum machining
parameters for cutting Al are found at the level where each factor
has the largest S/N ratio. Therefore, the optimal machining
conditions for tool life were found to be the cutting speed of
1000rpm, feed rate of 0.1 mm/rev, depth of cut of 0.2 mm. Thisis Figure 3.3 (a) S/N ratios graphs of responses for
supported by the results of the sensitivity graph of the mean aluminium alloy (4%SiC/B4C); (b) Main effects plot for
cutting condition as shown in Fig. 3.1(b). means for aluminium alloy (4%SiC/B4C)

The aim of this study is to determine the optimum conditions for

cutting Al (4%SiC/B4C) using three types of cutting
parameters. One of the methods used to analyse data for
process optimization uses SN ratio. Fig.3.3 (a) shows the mean
of SN ratio for larger-the-better characteristics of tool life
obtained using Minitab 15. The slope of the graphs clearly
shows thatthe feed rate is the most significant factor, followed by
the type of depth of cut and cutting speed.Based on Fig.3.3 (a),
the optimum machining parameters for cutting Al are found at
the level where each factor has the largest S/N ratio. Therefore,
the optimal machining conditions for toollife were found to be
the cutting speed of 3000rpm, feed rate of 0.1 mm/rev, depth of
cut of 0.2mm. This is supported by the results of the sensitivity
graph of the mean cutting condition as shown in Fig. 3.3 (b).

Figure 3.2 (a) S/N ratios graphs of responses for

aluminium alloy (2%SiC/B4C); (b) Main effects plot for
means for aluminium alloy (2%SiC/B4C)
 Table 3.1 Average s/n ratios for each factor and level with
regard to cutting of aluminium

Cutting Feed Depth of

Level
speed(rpm) rate(mm/rev) cut(mm)
1 3.1414 8.1738 1.4311
2 1.0493 .9758 3.1194
3 1.5859 -3.3729 1.2262
Delta 2.0921 11.5467 1.8932
Rank 2 1 3

The analysis of variance was conducted to determine which

machining parameters significantly affect the cutting of Al
(2%SiC/B4C). ANOVA was performed to find whether
individual factors and their interactions that affect the cutting of
Al (2%SiC/B4C) were meaningful. From the ANOVA results
Figure 3.4 (a) S/N ratios graphs of responses for presented in Table 3.6, the factor of cutting speed, depthof cut
aluminium alloy (6%SiC/B4C); (b) Main effects plot for
and feed rate significantly affected the cutting of Al
means for aluminium alloy (6%SiC/B4C)
(2%SiC/B4C). From Table 3.6, the most influential factor was
The aim of this study is to determine the optimum conditions for found to be the feed rate. The other important factors were
cutting Al (6%SiC/B4C) using three types of cutting cutting speed and depth of cut. In addition, the P-values for the
parameters. One of the methods used to analyse data for tool life with regard to the factor interactions were not
process optimization uses SN ratio. Fig.3.4 (a) shows the mean meaningful since they were greater than significance level.
of SN ratio for larger-the-better characteristics of tool life Hence, the statistical significance of interactions was minimal
obtained using Minitab 15. The slope of the graphs clearly and could be neglected.
shows thatthe feed rate is the most significant factor, followed
by the type of cutting speed and depth of cut. Based on Fig.3.4
Table 3.2 Average s/n ratios for each factor and
(a), the optimum machining parameters for cutting Al are found
level with regard to cutting of aluminium alloy
at the level where each factor has the largest S/N ratio.
Therefore, the optimal machining conditions for cutting were (2%SiC/B4C)
found to be the cutting speed of 2000rpm, feed rate of 0.1
mm/rev, depth of cutof 0.3 mm. This is supported by the results Cutting Feed Depth of
Level
of the sensitivity graph of the mean cutting conditionas shown speed(rpm) rate(mm/rev) cut(mm)
in Fig. 3.4 (b). 1 3.1414 8.1738 1.4311
2 1.0493 .9758 3.1194
3 1.5859 -3.3729 1.2262
3.2 ANALYSIS OF VARIANCE (ANOVA)
Delta 2.0921 11.5467 1.8932
Rank 2 1 3
The analysis of variance was conducted to determine
which machining parameters significantly affect the cutting of
Al. [4] ANOVA was performed to find whether individual
factorsand their interactions that affect the cutting of Al were The analysis of variance was conducted to determine which
meaningful. From the ANOVA results presented in Table 3.5, machining parameters significantly affect the cutting of Al
the factor of cutting speed, depth of cut and feed rate (4%SiC/B4C). ANOVA was performed to find whether
significantly affected the cutting of Al [4]. From Table 3.5, the individual factors and their interactions that affect the cutting
most influential factor was found to be the feed rate. The other of Al (4%SiC/B4C) were meaningful. From the ANOVA
important factors were cutting speed and depth of cut. In results presented in Table 3.7, the factor of cutting speed, depth
addition, the P-values for the tool life with regard to the factor of cut and feed rate significantly affected the cutting of Al
interactions were not meaningful since they were greater than (4%SiC/B4C). From Table 3.7, the most influential factor was
significance level. Hence, the statistical significance of found to be the feed rate. The other important factors were
interactions was minimal and couldbe neglected. depth ofcut and cutting speed. In addition, the P-values for the
tool life with regard to the factor interactions were not
meaningful since they were greater than significance level.
Table 3.3 Average s/n ratios for each factor and level with regard to cutting ofaluminium alloy (4%SiC/B4C)

LEVEL Cutting speed (rpm) Feed rate (mm/rev) Depth of cut (mm)

1 1.5416 6.3504 0.8420

2 2.6688 1.0836 2.0359

3 1.5466 -1.6769 2.8792

Delta 1.1272 8.0273 2.0373

Rank 3 1 2

The analysis of variance was conducted to determine which machining parameters significantly affect the cutting of Al (6%SiC/B4C).
ANOVA was performed to find whether individual factors and their interactions that affect the cutting of Al (6%SiC/B4C) were
meaningful. From the ANOVA results presented in Table 3.8, the factor of cutting speed, depthof cut and feed rate significantly affected
the cutting of Al (6%SiC/B4C). From Table 3.8, the most influential factor was found to be the feed rate. The other important factors
were cutting speed and depth of cut. In addition, the P-values for the tool life with regard to the factor interactions were not meaningful
since they were greater than significance level. Hence, the statistical significance of interactions was minimal and could be neglected.

Table 3.4 Average s/n ratios for each factor and level with regard to cutting ofaluminium alloy (6%SiC/B4C)

LEVEL Cutting speed (rpm) Feed rate (mm/rev) Depth of cut (mm)

1 3.1414 8.1738 1.4311

2 1.0493 0.9758 3.1194

3 1.5859 -3.3729 1.2262

Delta 2.0921 11.5467 1.8932

Rank 2 1 3

Table 3.5 ANOVA results for cutting of aluminium

SOURCE DF SS MS F-Value P-Value

cutting speed
2 0.1178 0.05892 0.63 0.545
(rpm)
feed rate
2 5.7927 2.89637 30.73 0.000
(mm/rev)
depth of cut
2 0.3356 0.16781 1.78 0.194
(mm)
Error 20 1.8848 0.09424

Total 26 8.1310
 Table 3.6 ANOVA results for cutting of aluminium alloy (2%SiC/B4C)

SOURCE DF SS MS F-Value P-Value

cutting speed
2 0.1178 0.05892 0.63 0.545
(rpm)
feed rate
2 5.7927 2.89637 30.73 0.000
(mm/rev)
depth of cut
2 0.3356 0.16781 1.78 0.194
(mm)
Error 20 1.8848 0.09424

Total 26 8.1310

Table 3.7 ANOVA results for cutting of aluminium alloy (4%SiC/B4C)

SOURCE DF SS MS F-Value P-Value

cutting speed
2 0.05671 0.02836 0.80 0.465
(rpm)
feed rate
2 2.53718 1.26859 35.58 0.000
(mm/rev)
depth of cut
2 0.22001 0.11001 3.09 0.068
(mm)
Error 20 0.71315 0.03566

Total 26 3.52706

Table 3.8 ANOVA results for cutting of aluminium alloy (6%SiC/B4C)

SOURCE DF SS MS F-Value P-Value

cutting speed
2 0.05671 0.02836 0.80 0.465
(rpm)
feed rate
2 2.53718 1.26859 35.58 0.000
(mm/rev)
depth of cut
2 0.22001 0.11001 3.09 0.068
(mm)
Error 20 0.71315 0.03566

Total 26 3.52706
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