Machining Behavior of Al-MMC Reinforced with Hybrid Additives: Effects of Cutting Parameters – A Taguchi Approach

Document Type : Research Article

Authors

Faculty of Materials and Manufacturing Technologies, Malek Ashtar University of Technology, Tehran, Iran

Abstract

Aluminum-based composites reinforced with Mg₂Si particles are valued for their engineering properties. This study examines how cutting parameters and Ag, Bi, and Sr additives affect tool wear and surface roughness during both dry and wet turning of Al–Mg₂Si composites. Using a Taguchi design, we varied spindle speed, feed rate, depth of cut, and lubrication to determine their relative impacts on tool wear area and surface roughness. Composites were fabricated through casting and examined using SEM–EDS techniques to assess microstructural characteristics and wear morphology. Feed rate emerged as the most critical factor, while wet machining with a biodegradable fluid markedly improved both tool life and finish. Among the materials tested, the composite containing all three additives delivered the lowest wear and finest surface. Specifically, the 14.47% improvement in dispersion uniformity was observed when all additives were used, while tool wear was reduced by 24.04%, and surface roughness improved by 18.94% under optimized machining conditions (spindle speed of 1000 rpm, feed rate of 0.12 mm/rev, and depth of cut of 1 mm). Regression modeling supported the experimental findings and demonstrated strong predictive accuracy. Confirmation trials under optimized conditions verified these trends. These results highlight the role of additive elements not only in modifying microstructure but also in enhancing machinability. The findings provide clear guidance on selecting additive combinations and machining settings to maximize productivity, extend tool life, and achieve superior surface integrity in Al–Mg₂Si composite turning.

Keywords

Main Subjects

References

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Mechanics of Advanced Composite Structures
Volume 14, Issue 1 - Serial Number 29
In Progress
April 2027
Pages 165-180

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