Experimental Investigation of Micro Groove Textured Cutting Inserts and Its Design Parameter Effects on Machinability Aspect During Turning of AL_MMC

Abstract

Machining is a material removal process in which better surface quality, minimum tool wear and power consumption are the basic requirement of manufacturing industries. Cutting condition is also a play a significant role to enhance the machinability characteristics. Metal Matrix Composite (MMC) is a combination of metal as matrix and ceramic particles are reinforcement material. It is classified as light weight material and widely preferred in aerospace and automobile industries. Machining of MMC is a difficult task due to the presence of hard ceramic reinforcement presented. Another significant parameter in metal cutting is cutting fluid. Generally, hydrocarbon oil based cutting fluid is used in metal cutting industries which are also known as conventional cutting condition. The issues with conventional conditions are environmental pollution as well as operator health issues. To overcome the above issues, researchers are attempted different alternative cutting conditions. Few alternative cutting conditions are dry machining, vegetable oil as coolant, minimum quantity lubrication and ceramic coated tool. The limitations are observed with dry machining is metallurgical changes and heat affected zone. Flow properties and oxidation nature are the limitation with vegetable oil as cutting fluid. Equipment are required for coating and minimum quantity lubrication. Recently, researchers are used texturing on the rake face filled with solid lubricants. This can be acted as better alternative cutting conditions. Texturing is also known as called as microgroove. Micro groove is used to retain the solid lubricant and gets evaporation and form a thin lubrication when frictional contact during tool chip interfaces. Micro groove parameters are called design parameters. Performances of machining get affected by changing the design parameters. As mentioned earlier, solid lubricants are in powder form and get evaporation then form a thin lubrication layer.