Iranian Journal of  Manufacturing Engineering

Iranian Journal of Manufacturing Engineering

Investigating the Effective Parameters on Surface roughness and Material Removal Rate in Milling of Hybrid Aluminum Matrix Composites

Document Type : Original Article

Authors
1 Department of Mechanical Engineering, Arak University of Technology, Arak, Iran
2 BSc Student, Mechanical Engineering Department, Arak University of Technology, Arak, Iran
3 MSc Student, Mechanical Engineering Department, Arak University of Technology, Arak, Iran
10.22034/ijme.2025.523438.2084
Abstract
In recent years, due to the increasing demand from various industries such as military, aerospace, and automotive for materials with high strength-to-weight ratios, the use of metal matrix composites, particularly aluminum matrix composites, has significantly increased. Machining to achieve high dimensional accuracy is an integral part of the production process for products made with aluminum matrix composites. Due to the presence of reinforcing materials such as silicon carbide, machining these materials always faces many challenges. Therefore, studying the effective parameters on machining aluminum matrix composites is essential. In this study, using a systematic approach including statistical modeling and experimental testing by response surface methodology and extracting regression equations, the effect of spindle speed, feed rate, depth of cut, and percentage of reinforcing particles on surface roughness and material removal rate during milling of AL7075/SiC/Gr hybrid aluminum composite has been thoroughly investigated. Based on the studies conducted, it can be acknowledged that the results show that by increasing the feed rate, the material removal rate and surface quality improve. Also, increasing the cutting speed leads to a decrease in surface roughness due to the presence of graphite particles and an increase in the material removal rate. Also, the best combination of values was found to simultaneously minimize surface roughness and maximize material removal rate. The best combination of parameters is: spindle speed of 1000 rpm, feed rate of 0.0539 mm/rev, depth of cut of 1.267 mm, and 10% reinforcing particles of silicon carbide and graphite.
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Articles in Press, Accepted Manuscript
Available Online from 22 August 2025