OPTIMIZATION OF MATERIAL REMOVAL RATE (MRR) COATED AND UNCOATED CARBIDE CUTTING TOOL IN MILLING PROCESS OF MMC (Al-Si/10%AlN)

Abstract

Metal matrix composites (MMCs) are widely used in numerous industrial sectors because of its light weight, strong and hard. However, MMC Al-Si/10%AlN material that content elements of Aluminium, Silicon and Aluminium Nitride 10% is rough and abrasive in nature, which will greatly affect the tool wear. The purpose of this research is to determine the material removal rate (MRR) for Aluminium silicon alloy (AlSi) matrix composite, which has been reinforced with aluminium nitride (AlN), with three types of carbide inserts present. Experiments were conducted at various cutting speeds, feed rates and depths of cut, according to the Taguchi method, using a standard orthogonal array L27 (34). The signal-to-noise (S/N) ratio and analysis of Variance ANOVA are applied to study the characteristic performance of cutting speeds, feed rates, depths of cut and types of tool in measuring the MRR during the milling operation. Based on the results, the maximum MRR of 116.2 cm3 is achieved a cutting speed of 370 m/min, feed rate of 0.8 mm/tooth, depth of cut of 0.4 mm using TiB2 carbide tool. ANOVA results showed the factor of cutting speed, depth of cut and type of insert significantly affected the MRR. It was found that most influential factor was type of insert of 40.4%. The other important factors were feed rate (17.5%) and interaction cutting speed and feed rate (13%). The total volume of it is to be one of the goals in manufacturing because it is closely related to machining costs and profits.