International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

Fabrication of Hybrid Aluminium Metal Matrix

Composite Using Stir Casting and Analysis of
Machining Parameters
Venkatesan.K

School of Mechanical and Building Science,

VIT, Vellore, India
venkatesan.kannan@vit.ac.in

Johny James.S

School of Mechanical and Building Science,

VIT, Vellore, India
johnyjames2002@yahoo.com

Kuppan.P

School of Mechanical and Building Science,

VIT, Vellore, India
pkuppan@vit.ac.in
Abstract In this paper an attempt has been made
to fabricate hybrid aluminum metal matrix
composite with a composition of 7wt% Silicon
carbide and 3wt% Alumina using stir casting
method. Morphology of the composite and
reinforced particle distribution were studied by
optical microscopy. The fabricated cast composites
were carefully machined. The influence of
machining parameters like cutting speed (s), feed
rate (f) and depth of cut (d) on surface roughness
(Ra) and cutting force (F) was investigated during
experimentation.
The
optimal
machining
parameters have been found by Analysis of
Variation (ANOVA). Results shows that when
cutting speed increases surface roughness value
decreases. Also it shows cutting force is directly
proportional to cutting speed. Tool wear study has
been made to find out tool wear during machining.
It is concluded that tool wear is directly
proportional to depth of cut.
Keywords: Turning, Cutting speed, depth of cut,
feed rate, surface roughness, micro structure,
cutting force.
. INTRODUCTION

The need for engineering materials with the industrial

importance for the areas of aerospace and land vehicles
has led to a rapid growth of composite materials.
Composites have an edge over monolithic materials
because of their unique properties such as high specific
strength and stiffness, increased wear resistance,
corrosion
resistance,
improved
temperature
performance together with better thermal and fatigue
and creep resistance [1]. Metal matrix composites are
one of the main innovations in the improvement of

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advanced materials. Among the different matrix

materials available, aluminum and its alloys are widely
utilized in the fabrication of MMCs and have reached
the industrial production stage. The emphasis has been
given on improving reasonable Al-based MMCs with
different hard and soft reinforcements (SiC, Al2O3,
graphite, and mica) because of the enhanced
possibilities of these combinations in forming highly
desirable composites [2]. However, some information
is available regarding Al2O3 particulates reinforced in
various aluminum metal matrix [3]. The special effects
of SiCp in Al-4.5% Cu-1.5% Mg alloy on mechanical
properties of materials were investigated by Stefanos
[4]. He produced composite material using stir casting
route and concluded positive response on fatigue and
tensile strength in heat treated condition with addition
of SiCp and Al2O3. The stir cast aluminum alloy
matrix and process parameters were thoroughly
investigated by Pai, et. al.[5] . They conclude from
literature that stir casting process is reasonably simple
and less expensive as compared to other processing
methods. The most economical manufacture of such
composites is by stir casting. Production of composites
using stir casting process needs equal dispersion of
abrasive particles with the metal matrix. In order to
confirm equal dispersion decided to go for
microstructure study, because unequal distribution
results in poor hardness and poor wear resistance in the
above composite. MMCs have become necessary
materials in aerospace, marine and automobile
engineering application because of the light weight,
high strength, stiffness and resistance to high
temperature. However the final transfer of these
composites into final engineering products is
associated with machining either milling or turning.
Composites are always not easy to machine due to its
hardness and abrasive nature [6] this leads to rapid tool

International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

wear [6]. The hard abrasive particles come in contact

with tool surface and acts as small cutting edges [7].
These particles act as abrasive between cutting tool and
work piece. This results in high tool wear and poor
surface finish [7].
In the view of the above machining problems the
main aim of our work is to study the effect of different
cutting parameters on surface finish and tool wear. The
Taguchi L9 orthogonal array is utilized for the above
experiment. Analysis of variants is also carried out to
investigate the highest influencing machining
parameters on the surface finish and cutting force.
II. FABRICATION OF AL-SiC-Al2O3 METAL MATRIX
COMPOSITES

composition of 7 wt% and 3 wt% and particle average

size of 25 micron. The above mentioned composite
was prepared using stir casting process. The
experiments were performed on a lathe (turning
operation). The dimensions of the specimen were 250
mm in length and 30 mm in diameter as shown in the
fig 1.
The surface finish of the machined component was
measured, and the cutting force was measured using
dynoware software and respective tool dynamometer.
The cutting tool selected for machining the Al-SiCAl2O3 composite was Tungsten carbide inserts with
ISO code CNMG 120408 grade THM.

Silicon Carbide and alumina reinforced particles of

average particle size 25 microns respectively are used
for casting of Al-SiC-Al2O3 MMCs by stir casting
technique. In this study, Al6061 is used as metal matrix
reinforced with 7 wt% Silicon Carbide and 3 wt%
alumina particulates. The melting was carried out in a
steel crucible placed inside the resistance furnace. An
induction resistance furnace with temperature regulator
as well as indicator is used for melting of Al-SiCAl2O3 MMCs. The fig 1 shows an induction resistance
furnace and temperature regulator as well as indicator
respectively. SiC and alumina particulates were
preheated at 400C for 2 hours to improve the wet
ability by removing the absorbed hydroxide and other
gases.
The furnace temperature was first raised above the
melting temperature that is 800C, to melt the matrix
completely. At this stage the preheated SiC and Al2O3
particles were added and mixed. A small amount of
Magnesium is added in order to increase the wet ability
of the composite. Mechanical mixing was carried out
for 15min at 380rpm average stirring speed. Mould
prepared of thick steel sheet was preheated to 250C
for 2.00 hours before pouring the molten Al-SiC-Al2O3
MMC. The chemical composition of the composite is
shown in Table 1.
III. EXPERIMENTAL PROCEDURE

In this experiment, the material to be machined is 6061

Al reinforced with SiCp and Al2O3 particles at a

Fig.1.Specimenfixedforturningoperation

IV. RESULT AND DISCUSSION

The optical micrographs of Al6061 with 7% SiC and

3% Al2O3 volume fraction of particle reinforcement are
shown in the fig 2(a) and fig 2(b). Micro structural
analysis of the specimen shows that the SiC and Al2O3
reinforcements are evenly distributed in the metal
matrix.

Table1. Chemical composition of Al 6061 T6 -SiC (7%)-Al2O3 (3%)

Reinforcement
SiC and Al2O3
(30m-avg)

%Al

Balance

%Mg

%Si

%Fe

%Cu

%Zn

0.81-

0.42-

Max

0.115-

Max

1.20

0.80

0.73

0.4

0.25

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%Ti

Max 0.15

%Mn

%Cr

Max

0.04-

0.155

0.355

Others

0.053

International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

Fig.2.Microstructure of Al 6061 reinforced with 7%SiC and 3% Al2O3

Table 2: Machining Parameters and their levels.

Process factor

Unit

Notation

Cutting speed (A)

m/min

Feed rate (B)

Depth of cut (C)

Level
1

50

75

100

mm/rev

0.206

0.411

0.588

mm

0.25

0.5

0.75

Table 3: Taguchi L9 Orthogonal array for Surface roughness and Cutting force

Levels

Cutting

Feed rate

speed

Surface roughness (Ra) in

Cutting force F in

Depth of cut

microns

3.580

37.22

3.030

159.6

2.090

284.5

3.280

55.66

3.074

89.68

3.200

72.53

3.750

159.0

3.221

92.91

3.819

72.72

Analysis of variance (ANOVA) is a method used in

statistical design of experiments. The factors have been
adjusted to measure responses while attempt is made to
determine its effect. The ANOVA was performed at 95
percent confidence level.
From Table 4 it is undoubtedly understood that, cutting
speed has the contribution on surface roughness is
34.54 percent, feed rate is17.82 percent, interaction

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1411

Effect of cutting speed with depth of cut is15.25

percent and interaction effect of cutting speed with
feed rate is14.81percent. It is also noted that the depth
of cut has a contribution of 9.34 percent on surface
roughness.

International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

Table 4: Analysis of variance for surface roughness

Source

Sum of
square

DOF

MSS

Table 5: Analysis of variance for Cutting force

Source

Sum of
square

DOF

MSS

%
contribution

contribution

0.72802

0.728017

34.54

4090.9

4090.91

8.715

0.3755

0.001045

17.82

5274.1

1540.2

11.236

0.19693

0.029403

9.34

18209.4

1610.32

38.79

AxA

0.00811

0.008107

0.3848

AxA

7613.4

7613.37

16.22

BxB

0.06349

0.004267

3.013

BxB

0.4

63.93

8.522x10-4

CxC

0.1002

0.030104

4.755

CxC

1419.7

41.79

3.02

AxB

0.31337

0.040508

14.8716

AxB

10034.7

6113.96

21.379

AxC

0.32155

0.321554

15.259

AxC

293.2

293.16

0.624

Error

Error

Total

2.10716

Total

46935.9

Fig.3.Main effect plots for surface roughness

From the main effect plot diagram for surface
roughness shown in the fig 3, the best machining
parameter for good surface finish was determined as
cutting speed 50m/mm, feed rate 0.588mm/rev and
depth of cut 0.75mm.
From Table 5 it is clearly understood that the depth of
cut has high contribution on cutting force which is
38.79 percent, followed by the interaction of cutting
speed with feed rate is 21.379 percent and squared
cutting speed is16.72 percent, feed rateis11.236 percent
and cutting speed is 8.715 percent.

Fig.4.Main effect plots for Cutting force

Form the main effect plot for cutting force graph
(fig.4.), the best machining parameters for good cutting
force have been determined as cutting force 75m/mm,
feed rate 0.206mm/rev and depth of cut 0.25mm.
Tool wear
Tool wear enhances gradual breakdown of cutting tools
due to continuous operation. fig 5 shows the image of
new insert CNMG 120408 THM.

Fig.5.Image of new insert CNMG 120408 THM

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International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

After each level of machining with

corresponding machining parameters the inserts cutting
edge has been worn out due to the machining of
composite which consists hard particles like SiC and
Al2O3. The fig 6 shows the respective images of the
insert cutting edges used in the machining process.

Factors
Optimum value
for surface
roughness (Ra)
Optimum value
for cutting force
(F)

Cutting
speed
(m/min)

Feed rate
(mm/rev)

Depth
of cut
(mm)

50

0.588

0.75

75

0.206

0.25

4. Tool wear was caused due to high cutting speed and

high depth of cut.
ACKNOWLEDGEMENTS
The authors are grateful to School of
Mechanical and Building Sciences, VIT University for
providing the facilities of the Centre for Advanced
Materials Research under FIST-DST for carrying
out this work. The authors would like to thank Mr. P.
Mohan, workshop instructor, for providing technical
skill to this experimental work.
REFERENCES

Fig.6. Image of worn out inserts after machining.

From fig 6 it has been noticed that few inserts has
significant amount of built up edges. This is because of
the aluminiums affinity to stick to the cutting edge of
the insert. It is found that this built up edges is due to
high depth of cut
V.CONCLUSION
1. Taguchis design and analysis (L9 orthogonal array)
method is suitable to optimize the surface roughness
(Ra) and cutting force (F) in this work.
2. The contribution of machining parameters on
surface roughness is investigated and mentioned
below.
A) Cutting speed is 34.54 percent.
B) Feed rate is
11.24percent.
C) Depth of cut
09.34 percent.
And concluded cutting speed is the most influential
factor on surface roughness criteria in the experimental
study.
3. The contribution of machining parameters on cutting
force is investigated and mentioned below.
A) Cutting speed is 8.71 percent.
B) Feed rate is
17.82 percent.
C) Depth of cut
38.79 percent.
And concluded depth of cut is the most influential
factor on surface roughness criteria in the experimental
study.
3. Using design of analysis the below optimized
machining parameters are tabulated for better surface
finish and lowest cutting force.

[1].
Das, S., "Development of Aluminum Alloy
Composite for Engineering Applications, Indian
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August, 2004.
[2]
T.Sasimurugan, K.Palanikumar., Analysis of
the Machininh Charecteristics on Surface Roughness
of a hybrid Aluminium Metal Matrix Composite
(Al6061 SiC-Al2O3 ), Journal of Minerals & Materials
Characterization & Engineering, Vol. 10, No.13,
pp.1213-1224, 2011.
[3]
Redsten, A.M., Klier, E.M., Brown, A.M.,
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D.C.,
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Aluminum", Journal of Materials Science and
Engineering, Volume A 201, pp. 88-102, 1995.
[4]
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SiC Reinforced with Al 4.5% Cu-1.5% Mg Alloy",
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[5]
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[6]
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[7]
T.Sasimurugan
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K.palanikumar.,
Analysis of the machining characteristics on surface
roughness of a hybrid aluminium metal matrix
composite (Al6061-SiC-Al2O3)
---------------*Corresponding author. Tel : +919443628085

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