Machining performance analysis of Al 7075/ferrochrome metal matrix nanocomposite using uncoated carbide insert towards environmental sustainability

Aluminium metal matrix composites are profoundly utilized in the aerospace, automobile, and marine sectors owing to their enhanced mechanical qualities, such as a high strength-to-weight ratio and corrosion resistance. This work focuses on analysing the influence of various machining parameters, specifically cutting speed, feed rate, and depth of cut, on noise emission and hardness during the turning process of Al7075 reinforced with 5 wt.% Fe-Cr composites. The studies were conducted on a CNC lathe using uncoated carbide insert employing a Taguchi L9 orthogonal array. At run 5, with a cutting speed of 110 m/min, a feed rate of 0.1 mm/rev, and a depth of cut of 0.3 mm, a greater noise level (79.5 dB) was obtained. The maximal hardness of 167 HV was reached at run no. 3 (cutting speed: 60 m/min, feed rate: 0.15 mm/rev, and depth of cut: 0.3 mm). The ANOVA findings indicated that cutting speed significantly influences both noise emission and hardness. Multiple linear regression models for both Ne and H are found to be significant as R2 approaches 1 with p-value <0.05 and obtained optimal parameters through desirability approach. The research findings provide insights for improving machining performance during the turning of AMMC composites.