Abstract

In this experimental study, composite samples containing silicon are produced with powder metallurgy technique by sintering under argon atmosphere. The effect of cutting speeds, feed rates and different cutting tool types on cutting forces and surface roughness are investigated in the face milling operation of silicon carbide particle reinforced aluminium metal matrix composites. Machining operations are conducted using coated and uncoated tools. Main cutting force (F_x) and surface roughness (Ra) are measured for at four different cutting speeds (300, 350, 400 and 450 m/min) and three different feed rates (0.1, 0.15, 0.20 mm/tooth) and two depth of cut (0.5, 1 mm). As a result of experimental evaluation for coated and uncoated tools, main cutting force increased with increasing feed rate and depth of cut whereas, it is decreased significantly by higher cutting speed. On the other hand, Al-SiC produces the worst surface finish with increasing feed rate and depth of cut in the uncoated tools whereas, the surface roughness in the coated tools are decreased under the same cutting conditions. The best surface roughness is obtained with increasing cutting speed for both uncoated and coated tools.

Key words: Metal matrix composite, face milling, machining, cutting forces, surface roughness.