Optimization of process parameters during machining of thixoformed A356-5TiB2 in-situ composite using Design of Experiments

Abstract

The current work emphasizes Aluminum based metal matrix composites with TiB2 as reinforcement are emerging materials because of their potential for applications in automotive and aerospace industries. The machining of these materials has become a very important subject for research. This paper presents the application of Design of Experiments and analysis of variance in optimizing the machining process parameters such as cutting speed, feed rate and depth of cut, during turning operation. The response considered for the analysis was surface roughness. The results indicated that A356-5TiB2 composite produces higher tool wear, surface roughness and minimizes the cutting forces. Moreover, there was improvement in the quality of the machined surface in the A356-5TiB2 composite compared to A356 alloy. The chips formed during turning were characterized by Scanning Electron Microscope and analyzed from the machinability point of view. Optimum machining parameters for minimizing the surface roughness were determined. Thus, this work is an attempt to study the machinability behavior of thixoformed A356-5TiB2 in-situ composites.