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<p>This work is dedicated to optimizing the machining performance of cutting tools while machining aluminum metal matrix composites (Al-MMC) using force measurement and material removal rate (MRR) analysis. The investigation conducts a comparative analysis between coated and uncoated inserts, focusing on assessing wear characteristics and MRR while highlighting the impact of machining parameters on tool performance. The experimental setup integrates a dynamometer and precision machining tool, emphasizing both coated and uncoated inserts. Through systematic experimental trials, wear rates and MRR values are quantified, contributing to a comprehensive understanding of the factors influencing tool wear and machining efficiency in Al-MMC. Observations reveal that variations in feed rates correspond to changes in cutting forces, directly affecting wear rates. The study underscores that coated inserts exhibit slower wear rates and stable MRR compared to their uncoated counterparts, emphasizing the trade-off between initial cost and long-term performance. The investigation expands its focus to different alloys within Al-MMC, specifically Al 6063, 6082, and 7075, under varying spindle speeds and feed rates, while maintaining a consistent depth of cut. Employing uncoated inserts at specific parameters, Al 7075 demonstrates superior strength, evidenced by reduced wear removal compared to Al 6063 and 6082. Additionally, using a coated insert in the 6% ZrB2 composite reveals diminished strength in Al 6082 due to the resultant cutting force when compared to Al 6063 and 7075. Further experiments with 9% and 12% ZrB2 composites highlight material-specific force variations, emphasizing the influence of alloy composition on machining capabilities. This study provides valuable insights into the machinability of Al-MMC materials, enhancing the understanding of alloy-dependent performance in machining operations. The research contributes crucial insights for optimizing machining conditions, selecting appropriate tool materials, and balancing wear resistance with efficiency. This research lays the groundwork for enhanced productivity and component quality in Al-MMC industries, providing valuable insights into tool wear and material removal rates to support future machining advancements.</p> Graphical abstract <p></p>

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Machining of hybrid Al alloys: a metal cutting parameters measurement approach

  • 期刊论文

  • 发表日期：

    2025年5月15日

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  • A. J. Pawar,
  • Ajeet B. Bhane,
  • Sagar D. Shinde,
  • Bapurao G. Marlapalle,
  • S. P. Komble,
  • R. N. Yerrawar,
  • Prashant J. Ambhore,
  • S. H. Gawande

摘要

This work is dedicated to optimizing the machining performance of cutting tools while machining aluminum metal matrix composites (Al-MMC) using force measurement and material removal rate (MRR) analysis. The investigation conducts a comparative analysis between coated and uncoated inserts, focusing on assessing wear characteristics and MRR while highlighting the impact of machining parameters on tool performance. The experimental setup integrates a dynamometer and precision machining tool, emphasizing both coated and uncoated inserts. Through systematic experimental trials, wear rates and MRR values are quantified, contributing to a comprehensive understanding of the factors influencing tool wear and machining efficiency in Al-MMC. Observations reveal that variations in feed rates correspond to changes in cutting forces, directly affecting wear rates. The study underscores that coated inserts exhibit slower wear rates and stable MRR compared to their uncoated counterparts, emphasizing the trade-off between initial cost and long-term performance. The investigation expands its focus to different alloys within Al-MMC, specifically Al 6063, 6082, and 7075, under varying spindle speeds and feed rates, while maintaining a consistent depth of cut. Employing uncoated inserts at specific parameters, Al 7075 demonstrates superior strength, evidenced by reduced wear removal compared to Al 6063 and 6082. Additionally, using a coated insert in the 6% ZrB2 composite reveals diminished strength in Al 6082 due to the resultant cutting force when compared to Al 6063 and 7075. Further experiments with 9% and 12% ZrB2 composites highlight material-specific force variations, emphasizing the influence of alloy composition on machining capabilities. This study provides valuable insights into the machinability of Al-MMC materials, enhancing the understanding of alloy-dependent performance in machining operations. The research contributes crucial insights for optimizing machining conditions, selecting appropriate tool materials, and balancing wear resistance with efficiency. This research lays the groundwork for enhanced productivity and component quality in Al-MMC industries, providing valuable insights into tool wear and material removal rates to support future machining advancements.

Graphical abstract