Effect of Machining Parameters on Cutting Forces and Surface Roughness in Al-(1-2) Fe-1V-1Si Alloys

Two Al-alloys with compositions Al-1Fe-1V-1Si and Al-2Fe-1V-1Si were cast in the form of plates to study machinability. The paper deals with the effect of Fe on machinability of Al-Fe-V-Si alloys subjected to milling operation using high speed steel end milling cutting tool. The results show that cutting force increases with increasing depth of cut and feed rate, and decreases with increasing cutting speed. From the experimental results, it is observed that cutting force is most significantly affected by the depth of cut, followed by feed rate and cutting speed. The studies also underline the fact that surface finish improves with decrease in feed rate and an increase in cutting speed. The optimum cutting speed zone lies in the range 125 to 175 m/min for machining of above Al alloys, where cutting forces are almost independent of cutting speed. High speed, low feed rate, and low depth of cut are recommended for better surface finish. The chips formed were also observed. It is observed that as Fe content increases from 1% to 2%, cutting forces increase appreciably with increase in the depth of cut, while for other parameters cutting forces are relatively stable.