Investigating the Parameters Affecting Surface Quality, Metal Removal Rate, and Tool Wear in Machining of Hybrid Metal Matrix Composites

Due to the significant increase in demand for materials with new capabilities, the use of composite materials is increasing. These materials have unique properties such as high wear resistance and a high strength-to-weight ratio, and are used by engineers in various industries, particularly in the aerospace and automotive sectors. Due to the metallic nature of these materials, the machining process is an integral part in achieving the shape and properties of the final product. Among composite materials, aluminum-based composites are the most widely used in industry. In this study, a methodical was conducted, study including statistical modeling using the response surface method and deriving regression equations of the effect of spindle rotation speed, feed rate, and depth of cut on surface roughness, metal removal rate, and tool wear during machining of A359/B4C/Al2O3 matrix aluminum composite. It was found that an increase in spindle rotation speed, feed rate, and cutting depth increased metal removal. The best combination of parameters that was found to simultaneously minimize the surface roughness and maximize the metal removal rate and minimize flank wear was a spindle speed of 600 rpm, a feed rate of 0.075 mm/rev, and a cutting depth of 0.20 mm