A novel investigation on effect of process parameters on optimization of feed and spindle speed levels for surface roughness and cylindricity tolerance while drilling Al6061 composite fabricated by liquid stir casting method with different weight fractions of Sic and comparing it with as cast Al6061

The primary goal of this study is to determine the average cylindrical tolerance and surface roughness of Al6061 metal matrix composites (MMCs) with varying weight fractions of Silicon Carbide (SiC) and compare them to as-cast Al6061. The Al-SiC MMC plate utilised in this investigation was 10 mm thick and 150×150 mm in size. Al-SiC MMC composites with different SiC weight fractions were produced using the stir casting method (5 %, 10 %, and 15 %). Before being stir cast at 800 ℃, the SiC reinforcements were heated to 650 °C. The cylindrical tolerance and surface roughness were measured using an ASTM standard. The control group (N=39) and the experimental group (5%, 10%, and 15% weight of SiC/Al MMC) each received test samples on each plate (N=13×4⨰3) taken from it (as-cast Al6061). one way ANOVA using spss software Aluminum MMC with 15% weight of SiC has considerably higher surface roughness and cylindrical tolerance (5.9633 µm, 0.095 µm), Aluminum MMC with 10% SiC surface roughness and cylindrical tolerance (5.3833 µm, 0.134 µm), Dramatically Aluminum MMC with 5% SiC surface roughness and tolerance (4.3133 µm, 0.131 µm), and cast Aluminum 6061 surface roughness and cylindrical tolerance (3.1833 µm,0.214 µm) than Aluminum MMC (with 10% and 5% weight of SiC) and as-casted Aluminum 6061 surface roughness and cylindrical tolerance with significance level of 0.0. Within the limits of this work, increased SiC reinforcement resulted in improved mechanical and physical characteristics, with 15% SiC reinforcement resulting in a significant increase in the above properties of Al-SiC metal matrix composites.