Study on tool wear and surface roughness in end milling of particulate aluminum metal matrix composite: Application of response surface methodology

Metal matrix composites have been widely used in industries, especially aerospace industries, due to their excellent engineering properties. However, it is difficult to machine them because of the hardness and abrasive nature of reinforcement elements like silicon carbide particles (SiCp).In the present study, an attempt has been made to investigate the influence of spindle speed (N), feed rate (f), depth of cut (d) and various %wt. of silicon carbide (S) manufactured through stir cast route on tool flank wear and surface roughness during end milling of LM25 Al-SiCp metal matrix composites. Statistical models based on second order polynomial equations were developed for the different responses. Analysis of variance (ANOVA) was carried out to identify the significant factors affecting the tool flank wear and surface roughness. The contour plots were generated to study the effect of process parameters as well as their interactions. The process parameters are optimized using desirability-based approach response surface methodology.