Abstract

Metal matrix composites containing fly ash as reinforcement are primarily preferred because these materials possess lower density and higher strength to weight ratio. While turning Aluminum fly ash composites, presence of hard ceramic particles in the fly ash leads to the failure of the cutting tool. However the presence of the hard ceramic particulates in the composites induces hetrogeneous structure which causes chipping of the cutting tool during intermittent turning application. Selection of optimal cutting conditions for a given machining process is utmost important to enhance the tool life during intermittent turning operation. Thus the research work was aimed at the experimental investigation of the tool life during intermittent turning of Al6061 composites containing 0% to 15% of fly ash. The experiments were carried out following ISO3685 standards. Tungsten carbide inserts of grade K10 and CGGN120304 style inserts were the turning tools. The cutting speed selected was 150m/min, 300m/min, 450m/min, 600m/min and 750m/min, feed of 0.08 mm/revolution, 0.12mm/revolution, 0.16mm/revolution and radial depth of 1.2 mm. The experimental results revealed that the performance of K10 grade carbide insert found better when composites machined below 600 m/min cutting speed and feed of 0.08 mm/revolution irrespective of percentage fly ash.

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