Cutting Force and Surface Roughness Analysis During Turning of Al 7075 Based Hybrid Composites

This paper presents the influence of cutting parameters like cutting speed, feed rate, and depth of cut on cutting forces and surface roughness in dry turning of three hybrid composites, viz. (i) A17075-10%SiC-0.1% B4C, (ii) A17075-10%SiC-0.1% Graphene, and (iii) A17075-10%SiC-0.1% CNT using uncoated and Diamond-]Like Carbon (DLC) coated carbide tool. The composites were fabricated via combined stir and squeeze casting method with ultrasonic vibration for homogeneity. The experimental results implied that the feed rate was the most dominant factor on the surface roughness. Lowest feed rate (0.1mm/rev) offered minimum surface roughness on three composites 1.1961um, 0.4428 um, and 0.5995um respectively. Presence of graphene showed a minimum surface roughness (0.4428 um) than that of the composites based on carbon nanotubes (CNT) and B4C. Depth of cut (1.5mm) was the most influencing factor on the cutting forces on all composites. Graphene(383.4N) and CNT-composites (318.6N) required higher cutting force than the B4C composite (264.3N) for dry turning at a depth of cut of 1.5 mm using DLC coated carbide tool. Taguchi L18 orthogonal-]array decided the number of experiments. Grey relational analysis was used to optimize the cutting parameters for minimum surface roughness and cutting force. (C) 2019 The Authors. Published by Elsevier Ltd.