Experimental Studies and Analysis of Turning Parameters of Aluminium Hybrid Composite (Al-Al2o3 5% -Sic 5%-Csa 6%) Using Rsm

Abstract

The demand for lightweight and high-performance materials led to the creation of aluminium hybrid composites (AHCs) that are well known for their remarkable mechanical properties. However, because of their abrasive and heterogeneous nature, AHCs are still difficult to machine. This study examines the impact of CNC turning settings on stir-cast aluminium hybrid composites (Al-SiC 5%-Al2O3-5%-CSA 6%). Three machining parameters, including depth of cut, feed rate (0.103–0.294 mm/rev), and cutting speed (80–120 m/min), were used to machine the AHC using CNC. Three input factors were taken into consideration when designing the trials utilizing a Box-Behnken Design in Response Surface Methodology (RSM) with process parameters of depth of cut (0.3–0.9 mm), feed rate (0.103–0.294 mm/rev), and cutting speed (80–120 m/min). Additionally, surface roughness (Ra) is performed to analyze smoothness of the samples using a Mitutoyo SJ-210 tester. Analysis of Variance was used to determine the machining parameters. Three out- of-bounds machining parameters were considered, such as surface roughness, material removal rate and machining time. The mathematical equation for three outputs was formulated by using design expert software. Results indicated that feed rate and cutting speed were the most significant parameters affecting surface roughness. Interaction effects were also significant, especially between feed rate and cutting speed. The optimized parameters reduced surface roughness from 8.617 μm to 2.145 μm. Validation experiments confirmed the accuracy of the RSM model. This study offers insights for industrial applications in industries including sports equipment, automotive, and aerospace and shows how well RSM works to optimize machining parameters for AHCs.