Tool Wear Parameter Optimization in Machining a Squeeze-Cast Metal Matrix Composite (Al6061-SiC)

In this research work, machining operations on an aluminum matrix composite (AMC) were optimized for improving the wear of high-speed steel tools. The squeeze casting method was used to manufacture the AMC, which had Al-6061 as matrix material and silicon carbide (wt. 15%) microparticles used as reinforcement. Feed rate (Fr), cutting speed (Cs), and depth of cut (Dc) were selected to optimize HSS tool wear rate. Using the Box–Behnken design, seventeen experiments were performed to analyze the single-factor effects and interaction effects of the process parameters on HSS tool wear rate. Experimental results show that optimal tool wear (0.964) was achieved at a Cs of 80 m/min, Fr of 0.2 rev/min, and Dc of 0.8 mm.