A case study of machinability evaluation of a gravity cast hypereutectic Al-Si binary MMC in dry turning

Hard Si particles when dispersed widely throughout a eutectic a-Al matrix forms hypereutectic Al-Si bin-ary alloy which is actually a simple in situ metal matrix composite (MMC). Hence, like other Al MMCs, they offer amalgamation of high strength-to-weight ratio and excellent wear resistance properties with high specific elastic modulus, exceptional heat-resistance and low thermal expansion and hence, are used in many industries. Machining of such materials like all other Al alloys is a challenging task mostly because of formation of built-up edges (BUEs) and long continuous chips. A case study of machinability evaluation of such a hypereutectic material with excess Si contents manufactured by gravity cast is presented. The study has been accomplished through investigation and analysis while carrying out turning experiments on a lathe by coated carbide tool inserts. The Taguchi orthogonal array is used for design and Response Surface Methodology has been employed for regression analysis and optimization. (C) 2022 Elsevier Ltd. All rights reserved.