Taguchi’s methodology of optimizing turning parameters over chip thickness ratio in machining P/M AMMC

Effect of turning parameters on chip generation during machining aluminum composite is studied in this work. Turning of Al–4%Cu–7.5%SiC composite material prepared through powder metallurgy procedure was chosen as the workpiece, machined using uncoated carbide insert TNMG 120404. Chips produced during machining were studied by measuring the thickness and were used along with uncut chip thickness to determine the chip thickness ratio. 99.85% pure aluminum was added with 4% volume fractions of copper and with silicon carbide particulates of 7.5%. To visualize the distribution of reinforcement phases in matrix, scanning electron microscope is used. Taguchi’s methodology of design of experiments was adopted for designing a L9 (Latin square) orthogonal array for experimental investigation, and from analysis of variance, cutting speed influencing the formation of chip by 64.13%, continuing with depth of cut by 35.26%, was identified. Confirmation test accomplished with ideal conditions produces a better chip condition.