Performance analysis of micro textured cutting insert design parameters on machining of Al-MMC in turning process

Abstract

Turning operation is one of the primary machining operations and enhanced machining performance is obtained by its process parameters. In turning process, heat is generated and it must be removed from the machining zone. Now a days, hydrocarbon oil based cutting fluid is used and it generates environmental issues as well as operator health issues. Recently, textured cutting tool inserts are attempted towards sustainable machining. In this work, turning process is carried out on aluminium-metal matrix composite (Al-MMC) with micro hole textured cutting tool inserts. Micro hole texturing involves various parameters such as hole diameter, hole depth and pitch between the holes. The main aim of this work is to analyze the effect of micro hole design parameters on machining performance. The input parameters include diameter of the micro hole, pitch between hole and hole and depth. Process outcomes include surface roughness, tool wear and power consumption. The experiments are performed based on L9 Taguchi orthogonal array. The result revealed that micro hole textured tools with solid lubricant embedded cutting inserts and its design parameters influence machining performance. Texture with solid lubricant could act as alternative to hydrocarbon oil based cutting fluid and also chip breaker.

Keywords

• Turning process
• Al-MMC
• LASER
• Textured tool
• Design parameters