An investigation of cutting force and tool–work interface temperature in milling of Al–SiCp metal matrix composite

Aluminium–SiC particulate metal matrix composites have attracted much interest in recent years among practitioners and researchers in the field of aerospace, automobile, nuclear, electronic packaging and other industries due to their low coefficient of thermal expansion, high strength and stiffness, hardness, wear and corrosion resistance properties. The present study focuses on aluminium A356 alloy with four different volume % of SiC particle–reinforced metal matrix composites synthesized by vacuum hot-pressing technique to achieve uniform dispersion of finer reinforcement over the matrix with higher densification. In order to study the machinability issues of the developed composites, computer numerical control end milling studies were conducted using central composite experimental design by varying cutting speed, feed and depth of cut, and the responses such as cutting forces and tool–work interface temperature were measured. The effect of machining parameters and reinforcement on the matrix during machining was analysed and optimized, which gives valuable guidelines to the manufacturing industries. The response surface models were developed and compared with experimental results. The results show that increase in volume % of SiCp reinforcement over the matrix results in higher tool–work interface temperature and needs higher cutting force during machining process.