Optimization of end milling parameters for rough and finish machining of Al-4032/3%SiC metal matrix composite

Abstract

Aluminum-based composites are known for better mechanical properties, superior corrosion performance, and light weight. Gradual increase in the reinforcement (SiC particles) produces improvement in several mechanical properties of Aluminum base alloy but adversely affects ductility. The present work depicts the end milling of the Al-4032/3%SiC composite. The investigation on the impact of end milling parameters has been attempted for rough and finish machining conditions. Two case studies (a) rough machining i.e., 100% weightage to material removal rate (MRR) (b) finish machining i.e., 80% weightage to surface roughness, and only 20% weightage to MRR have been investigated. Full factorial design with 3-factors at 3-level each has been used as the design matrix for conducting the milling experiments. Taguchi-based grey relational analysis (TGRA) has been adopted for the bi-objective optimization for finish machining. The significance of process parameters has been checked with analysis of variance (ANOVA).