Investigating the Tribological Aspects of Tool Wear Mechanism and Tool Life in Sustainable Lubri-Cooling Face Milling Process of Particle Reinforced SiCp/Al Metal Matrix Composites

In this paper, the face milling experiments were performed to investigate the cutting process of SiCp/Al (SiCp 65%) volume percentage and their effect on tool life and tool wear mechanism. The study was performed based on different cutting parameters (cutting speed vc, feed per tooth fz, and axial depth of cut ap, 1mm, and width of cut ae 8mm,) and cutting environments adopted as Dry MQL and CO2 Snow to analyze the effect of lubri-cooling machining process using polycrystalline diamond (PCD) cutting tools. A total of 18 experiments were performed during milling of SiCp/Al (65%) with each experimental run involved the 321 mm3 of the volume of material removal. The study found that lubrication and cooling can effectively reduce the tool wear and improve the tool life up to 29% for SiCp65% on moderate cutting parameters. The major wear mechanisms of PCD cutting tools are perceived as abrasive wear and adhesive wear mechanisms, which develop the flank wear and build-up-edge formations. Seemingly, a sub-zero cooling environment and dry cutting are found convenient to produce a build-up edge on the rake face of the cutting tool while MQL-assisted machining provides the benefit to prevent the cutting tool from material adhesion.