ABSTRACT
This paper presents the influence of cutting parameters like cutting speed, feed rate, and depth of cut on flank wear, crater wear, cutting force, surface roughness and cutting tool temperature using Uncoated and Diamond-Like Carbon (DLC) coated carbide inserts under dry turning of three hybrid composites, viz. (i) Al7075-10%SiC-0.1% B4C, (ii) Al7075-10%SiC-0.1% Graphene, and (iii) Al7075-10%SiC-0.1% CNT. The composites were developed through the combined stir and squeeze casting method with ultrasonic vibration. The experimental results revealed that highest flank wears recorded in the inserts during machining of B4C-based (0.9835mm) and the lowest in Graphene-based composites (0.2314mm) under considered experimental parameters. In the case of crater wear, the largest value observed for graphene-based (1.4373mm) and the smallest in B4C-based (0.3707mm) composites. The cutting tool temperature was observed to be maximum in Graphene-based (82.70C) and the minimum in B4C-based (73.10C) composites. Graphene-and CNT-composites required higher cutting force than the B4C composite for dry turning at feed rate 0.3 mm/rev and depth of cut of 1.5 mm using DLC coated carbide tool. Presence of graphene showed a minimum surface roughness than that of the composites based on carbon nanotubes (CNT) and B4C. Taguchi L18 orthogonal-array decided the number of experiments. Grey relational analysis was used to optimize the cutting parameters for minimum surface roughness and cutting force. However, the machinability of B4C composite was showed superior performance followed by the Graphene-based and CNT-based composites under considered machining parameters detailed in this research work.
