Multi-objective optimization of end milling process parameter for stir casted alumina reinforced aluminium metal matrix composite using RSM

Abstract

Modern manufacturing firms aim to attain quality, dimensional precision, increased production rate, minimal tool wear, economy and mainly surface roughness. Milling is becoming an essential material removal technique can be used for optimizing surface roughness of the composites for micro level and economic performance. Alumina reinforced Aluminium Metal Matrix Composites (AAMMC) developed by the stir casting method gives good mechanical properties and which is also used in many automotive, aerospace and industrial applications. This work focuses on the effect of end milling machining process parameters such ascutting speed, feed rate, depth of cut on machining of stir casted AAMMC. Alumina content of 10wt% is reinforced with Aluminium matrix is used for this research work, it was found that AAMMCs provide higher strength to weight ratio, wear resistance and hardness properties. Optimal levels and important end milling machining parameters were obtained using ANOVA and response surface methodology. The optimal values of surface roughness and the machining time were obtained at Cutting Speed of 1750 rev/min with a feed rate of 0.3 mm/rev and depth of cut 0.2mm. The predicted and measured values were interrelated with each other. This results determined that the model obtained using response surface methodology is utilized to analyse the Surface Roughness S.R and the Machining Time M.T of milling machining of AAMMC.