Machinability study of developed composite AA6061-ZrO2 and analysis of influence of MQL

Abstract

Aluminium metal matrix replaces high melting point and high density conventional materials, thus minimizing the usage of energy and supporting the environment. This work develops a low-weight, high-strength composite material with the help of AA 6061 and ZrO2 through a stir casting route incorporated with a squeeze casting setup. Machining and machining tools create impacts on clean environments, as they deal with lubricants and power consumption. Having taken this issue into consideration, this research studies the effect of machining parameters on surface roughness, tool wear, and cutting force, while turning the developed metal matrix composite in dry and minimum quantity lubrication conditions. The turning experiment was performed by designing parameters using an L27 orthogonal array. The turning condition was dry and with minimum quantity lubrication (MQL). The responses obtained in the turning process were analysed using the analysis of variance (ANOVA) technique to find the most influential factor and its percentage contribution. Optimal machining parameters were investigated and tabulated with the help of main effect plots and S/N ratio graphs. Studies prove that there is a linear relationship between MQL versus surface roughness and tool wear, and there was no substantial effect on cutting force.