Influence of machining parameters on metal removal rate and surface roughness of stir casted AA8011 hybrid metal matrix composite

Abstract The properties of AA8011 alloy include formability and high corrosion resistance of the alloy which has made it useful in a variety of applications. It is not however suitable in critical applications because it has low load-carrying properties compared to other aluminum alloys. In an attempt to increase the load-carrying capacity, AA8011 alloy is strengthened using titanium oxide and aluminum silicate. This composite is prepared with the help of the stir casting process. The stir-cast AA8011 containing 6 wt.% of Al 2 SiO 5 and 9 wt.% of TiO 2 enhanced its strength to its greatest extent in this investigation. A CNC turning process was also used to further machine the cast aluminum alloy to determine the rate of removal of the metal and surface roughness of the metal matrix composite. Response surface is a statistical method that was applied to optimize the parameters of the process. Surface roughness of 1.162 μm and metal removal rate of 18.024 mm 3 min −1 were achieved with a depth of cut of 0.7 mm, a feed rate of 0.08 mm min −1 and a cutting velocity of 150 m min −1 . The depth of cut, the feed rate, and the machining velocity are the main affecting process parameters as the results of the ANOVA test indicate.