An analysis of end milling performance on B4C particle reinforced aluminum composite

The present work investigates the influence of cutting parameters on the output responses such as temperature rise, chip formation, delamination, tool wear, and surface roughness during end milling of stir cast AA6351-B4C composite. The titanium nitride (TiN)-coated solid carbide tool with four flute end mill is used for the experiments. The thermography and scanning electron microscopy (SEM) images are used to analyze the effect of temperature rise on the chip formation and chip behavior. The increase in feed considerably increased the chip thickness from 0.7 to 1.2 mm at 2000 rpm. In addition to that, the formation of abrasive tool wear at minimum cutting speed has resulted with an increase in surface roughness. Further, the delamination of the slot entry surface is also assessed and achieved a lower delamination factor (<1.10) at 0.5 mm depth of cut condition. Finally, the desirability analysis is performed and found that the cutting speed at 2030 rpm, feed at 0.05 mm/tooth, and depth of cut at 0.5 mm are the suitable conditions to produce minimum temperature rise, lower delamination, and surface roughness simultaneously. The microscopic images revealed smooth surface with improved finish while machining at the optimum condition. The confirmation test results are also verified and found to be within 95% confidence and prediction intervals.