Investigation of tool wear and surface roughness during machining of ZA43–SiCp composite using full factorial approach

Abstract

This article presents the study of machinability of ZA43 alloy reinforced with silicon carbide particulate metal matrix composites. The specimen was fabricated through conventional liquid metallurgy technique. Silicon carbide with particle size of 60 µm with three different weight percentages (i.e. 5%, 10%, and 15%) was used for fabrication. Dry turning of composite specimens was carried out using uncoated and coated carbide indexible inserts on a conventional lathe. Comparisons of performance of each grade of the cutting tool were carried out in the experiment wherein 162 experiments were executed with the aim of determining surface roughness on the machined area of the composite and wear land on the flank portion of the cutting tool. The results were recorded and analyzed with a statistical analysis tool (analysis of variance) to identify the significant parameter influencing both surface roughness and flank wear. It was observed that cutting speed, feed, and depth of cut were the parameters affecting the surface finish and responsible for higher tool wear. The composition of the material also had substantial effect in deciding the surface roughness value and tool wear land.