Influence of Varied Percent Filler on Surface Roughness, Built Up Edge and Built Up Layer Formation

Abstract

Using Al6061 grade aluminum alloy and its hybrid composites reinforced with Redmud and Silicon carbide (Hmmcs) using K10 grade uncoated and coated tungsten carbide inserts as cutting tools, this study aims to analyse, built up edge and built up layer formation, as well as the relationship between machining parameters and surface roughness. Early cutting tool failure occurs during machining of Al6061 and its Hmmcs, primarily because of built-up edge formation. The formation of built-up edges causes a change in the cutting tools shape, which affects the rake angle and leads to increased cutting forces. The tool overhang, machining parameters, tool signature, machine stiffness, and machining conditions decide the surface finish and lay formation on the machined component. With a fixed depth of cut, varied cutting speed and feeds were the parameters to machine Al6061 and its composite material, which contains 3% redmud and 6% silicon carbide reinforcement. Results of the experiments showed that the cutting speed and feed significantly affect the formation of built- up edge and built-up layers, which in turn caused poor surface texture when machining hybrid metal matrix composites containing red mud and silicon carbide as reinforcement with Al6061.