Prediction of Vibration Amplitude and Surface Roughness in Machining of Al6061 Metal Matrix Composites by Response Surface Methodology

In this work, the Prediction of acceleration amplitude and surface roughness of Aluminium alloy (Al6061), reinforced with 15% Silicon Carbide particle (SiCp) metal matrix composites, has been made in the end milling process considering various machining parameters. The MMC was considered the difficult to machining due its reinforcement hardness and nature of abrasive element and the prediction of the amplitude and surface roughness are determined by conducting experiments on it. The experimental observations are used in a statistical method (RSM) and the mathematical prediction model is developed such that the Acceleration amplitude (φa) and surface roughness (Ra) are the response functions and the machining parameters, spindle speed (s), feed rate (f), depth of cut (d) and nose radius (r) are the design variables. The prediction model is used to determine the objective functions at different machining conditions and to analyses the effect of machining parameters on surface roughness and acceleration amplitude. The results of the model compared with the experimental results and found to be good agreement with them. The output of prediction model helps in selection of process parameters that reduce vibration and surface roughness, which ensures quality of milling process.