Exploring energy aspects and tool wear on dry turning of cupola slag-reinforced aluminium metal matrix composites

• Published in: Journal of the Brazilian Society of Mechanical Sciences and Engineering Vol. 46; no. 2
• Main Authors: Chakravarty, Soumyabrata, Sikder, Rakesh, Haldar, Partha, Nandi, Titas, Sutradhar, Goutam
• Format: Journal Article
• Language: English
• Published: Berlin/Heidelberg Springer Berlin Heidelberg 01-02-2024; Springer Nature B.V
• Subjects: Aluminum matrix composites; Carbide tools; Cutting force; Cutting parameters; Cutting wear; Engineering; Experimentation; Feed rate; Machinability; Mechanical Engineering; Metal matrix composites; Optical microscopy; Power consumption; Slag; Technical Paper; Tool life; Tool wear; Turning (machining); Weight; Machinability; Turning; AMCs; Cupola slag; Tool wear; Cutting force
• ISSN: 1678-5878; 1806-3691
• DOI: 10.1007/s40430-023-04651-7

This study investigates the dry turning of cupola slag reinforced aluminium metal matrix composites (AMCs) with the aim of exploring the energy aspects and tool wear. The study involves the fabrication of cast cupola slag reinforced Al–4.5–Cu matrix composites by the economic stir casting method with varying the weight percentage of cupola slag (3 wt.%, 5 wt.% and 7 wt.%) followed by dry turning using coated carbide tool. The experimentation involves process input parameters such as spindle speed, feed rate and weight percentage of slag and the experimentation has been designed using statistical full factorial methodology. The energy aspects have been evaluated by measuring cutting force and power consumed during machining and tool wear have been measured using optical microscopy. The results showed that the cutting force and power consumption increase with increasing speed and feed rate decreases with increasing slag concentration. Slag incorporation has a significant effect on machinability as it eases the turning process when compared with base alloy. Moreover, detailed analyses of the effect of process input on the responses have been studied along with rigorous comparison of machining quality. The findings can be useful in optimizing the cutting conditions for improved energy efficiency and tool life in the machining of similar materials.