OPTIMIZATION OF MACHINING AA4015/B4C METAL MATRIX COMPOSITES BY TAGUCHI METHOD

K. T. Thilagham (), P. C. Krishnamachary (), S. Saravanakumar (), A. Mahendran (), S. Kaliappan (), Manzoore Elahi M. Soudagar (), Sathish Kannan (), Sami Al Obaid () and Sulaiman Ali Alharbi ()
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K. T. Thilagham: Department of Metallurgical Engineering, Government College of Engineering, Salem, Tamil Nadu 636011, India
P. C. Krishnamachary: Department of Mechanical Engineering, J. B. Institute of Engineering and Technology, Hyderabad, Telangana 500075, India
S. Saravanakumar: Department of Mechanical Engineering, M. Kumarasamy College of Engineering, Karur, Tamil Nadu 639113, India
A. Mahendran: Department of Mechanical Engineering, Sona College of Technology, Salem, Tamil Nadu 636005, India
S. Kaliappan: Division of Research and Development, Lovely Professional University, Jalandhar – Delhi, G. T. Road, Phagwara, Punjab 144411, India
Manzoore Elahi M. Soudagar: Department of Mechanical Engineering, Graphic Era (Deemed to be University), Dehradun, Uttarakhand 248002, India
Sathish Kannan: Department of VLSI Microelectronics, Saveetha School of Engineering, Saveetha Institute of Medical and Technical Sciences, 602105, Chennai, Tamilnadu, India
Sami Al Obaid: Department of Botany and Microbiology, College of Science, King Saud University, PO Box – 2455, 11451, Riyadh, Saudi Arabia
Sulaiman Ali Alharbi: Department of Botany and Microbiology, College of Science, King Saud University, PO Box – 2455, 11451, Riyadh, Saudi Arabia

Surface Review and Letters (SRL), 2025, vol. 32, issue 02, 1-11

Abstract: This research investigates the impact of dry machining AA4015/B4C MMCs (metal matrix composites) utilizing an uncoated B4C insert on Flank wear (VBc) and surface roughness (Ra). This work attempts to close the knowledge gap on the effects of cutting parameters (feed, depth of cut, and speed) on tool wear and surface quality in machining technology. The primary rationale lies in optimizing machining processes for MMCs, known for their challenging machinability due to their tough metallic matrix and hard ceramic reinforcement. The study’s significance is underscored by the exploration of optimal processing parameters to minimize Flank wear and improve surface roughness, crucial factors influencing component quality and lifespan. Specifically, the research identifies v1-f1-d3 (VBc) and v3-f1-d3 (Ra) as the best process parameter combinations, significantly reducing both VBc and Ra. The obtained mathematical models for VBc and Ra provide statistically significant insights into the relationships between cutting variables and performance characteristics. The employment of Taguchi’s L9 orthogonal array proves invaluable in achieving these optimized process parameters efficiently. The Taguchi method’s advantage lies in its ability to systematically explore numerous variables and their interactions with minimal experiments. By reducing the number of trials required, this methodology streamlines the optimization process, saving time, resources, and costs while delivering enhanced machining performance for MMCs. This research, through its systematic approach and emphasis on optimized parameters, contributes to the advancement of machining techniques for MMCs, holding implications for various industrial applications demanding high-performance materials.

Keywords: Surface roughness; Flank wear; optimization; regression; Taguchi approach; modeling (search for similar items in EconPapers)
Date: 2025
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DOI: 10.1142/S0218625X24501087

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