Optimization of Machining Parameters of Al6061/SICMMCs Using Taguchi Approach
| International Journal of Mechanical Engineering |
| © 2025 by SSRG - IJME Journal |
| Volume 12 Issue 11 |
| Year of Publication : 2025 |
| Authors : Ajit Katkar, Bharat Sudame, Smita Nande, Ravindra Joshi, Amit Kasar, Amruta Patil |
10.14445/23488360/IJME-V12I11P107
How to Cite?
Ajit Katkar, Bharat Sudame, Smita Nande, Ravindra Joshi, Amit Kasar, Amruta Patil, "Optimization of Machining Parameters of Al6061/SICMMCs Using Taguchi Approach," SSRG International Journal of Mechanical Engineering, vol. 12, no. 11, pp. 67-77, 2025. Crossref, https://doi.org/10.14445/23488360/IJME-V12I11P107
Abstract:
Aluminum alloys are extensively used in transportation and process industries because they offer low mass, good thermal conductivity, and ease of fabrication. To support reliable machining of aluminum matrix composites for such applications, this work examines the turning performance of SiC‑reinforced Al6061 composites and determines optimal cutting conditions to balance quality and productivity. Al6061/SiC composites were produced by gravity die casting with reinforcement levels of 2–8 wt%. Optical microscopy and SEM/EDS confirmed a uniform dispersion of SiC particulates, clean particle–matrix interfaces, and the absence of detectable reaction products or porosity at the examined scales. Machining experiments were structured using a Taguchi L16 orthogonal array to study the influence of cutting speed (180–500 rpm), feed rate (0.1 mm/rev), depth of cut (0.3–1.2 mm), and SiC fraction on key outcomes: Surface Roughness (Ra), Material Removal Rate (MRR), and Tangential Force (Ft). Signal‑to‑noise analyses used larger‑is‑better for MRR and smaller‑is‑better for Ra and Ft, while ANOVA quantified factor significance. Results show that cutting speed is the primary driver for MRR, SiC content has the most potent effect on Ra, and depth of cut most strongly influences Ft. ANOVA corroborated these rankings, identifying cutting speed, SiC fraction, and depth of cut as the dominant contributors to variability in MRR, Ra, and Ft, respectively. The study provides practical parameter windows for turning Al6061/SiC composites, demonstrating that appropriate selection of speed, feed, and DOC can deliver smooth surfaces and competitive throughput despite the increased abrasiveness at higher SiC contents.
Keywords:
Analysis of Variance (ANOVA), Cutting speed, Material Removal Rate (MRR), Surface Roughness (Ra), Taguchi Method.
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