Machining behavior investigation of aluminium metal matrix composite reinforced with TiC particulates

The aim of this study is to investigate the impact of input factors, namely spindle speed (S_s), feed rate (F_r), and depth of cut (DOC), on the output response of surface roughness (R_a) and metal removal rate (MRR) during the dry turning process of AA-6061. The material under study, AA-6061, is strengthened with 6% and 8% weight of titanium carbide (TiC) particles, having an average particle size (APS) of 2 microns. To create experimental designs, the Box-Behnken design (BBD) of response surface methodology (RSM) and mathematical models were used. The desirability-function approach of RSM was applied to obtain optimal input factor values. The findings showed that, for 6% TiC composites, S_s had the greatest effect on both R_a and MRR, followed by F_r and DOC. Similarly, for 8% TiC composites, S_s had the most impact on R_a, followed by DOC and F_r, while DOC had the greatest influence on MRR. To validate the accuracy of the proposed models, confirmation tests were conducted. The outcomes of the confirmation test show that the proposed models are valid. The outcome of the study can be applied in manufacturing industries for optimizing machining processes, resulting in increased efficiency and reduced production costs.