Characterizing the tool wear morphologies and life in milling A520-10%SiC under various lubrication and cutting conditions

Metal matrix composites (MMCs) are lightweight and widely used materials constantly applied in various industries. Such material's structural and functional properties change under the contributions of various reinforcing particles and base materials. Multiple technologies are used in the manufacturing and machining these materials, and numerous studies are oriented toward this domain through academic and industrial projects. One aspect that receives less attention is understanding the combined effects of cutting parameters, lubrication conditions, and reinforcing elements on the machinability of such materials. Amongst MMC, limited attention has been paid to A520 alloys reinforced with SiC particles. Therefore, this work investigated the tool wear size and morphology in milling A520-10%SiC under various lubrication and cutting conditions. It was observed that cutting conditions significantly affect the tool life and wear morphology when machining A520-10%SiC. The main wear modes observed were abrasion and adhesion, mainly presented as the built-up edge (BUE) and Built-up layer (BUL). The wet method reduced the formation of BUE and BUL by 95% and MQL by 60% compared to the dry method. It was also observed that better tool life was observed under wet mode than readings made under MQL and dry modes. The outcomes could generate a practical window for the optimum selection of cutting parameters when machining reinforced Al-MMCs, in principle, A520-10%SiC.