Effect of tool wear on surface roughness in machining of AA7075/ 10 wt.% SiC composite

Quality of product and rate of production are affected by tool wear. Therefore, correct assessment of tool wear and its minimization is essential. Surface characteristics are affected by tool wear. AA7075/ 10 wt.% SiC (20–40 µm) composite was fabricated by stir casting process. Bars of 15 × 2.5 cm were obtained after casting. Initial machining was done on lathe machine by locally fabricated tool to remove the projections on casted bar and to bring size to 14 × 2.1 cm. Samples were also prepared for microscopic examination. Experiment were planned as per Design of Experiments (DOE) technique. Machining of AA7075/ 10 wt.% SiC composite bars was done by using carbide insert CNMG 120,404, 08,12EM, grade 6630 on CNC turning machine. The objective of this research is to study the effect of tool wear on surface roughness, during dry turning of AA7075/ 10 wt.% SiC (20–40 µm) composite. Tool wear and surface roughness were measured. Flank and Crater wear of inserts were extensively studied. Response surface methodology (RSM) was used for modeling to predict surface roughness and tool wear at different values of process parameters i.e. cutting speed, feed, depth of cut and nose radius, while turning AA7075/ 10 wt.% SiC composite. Experimental data of finish turning of AA7075/10 wt% SiC composite can be utilized by industries. Novelty of this research is that it contributes to practical features of composite machining know-how, due to discovering relations between tool wear and surface roughness, and pertinent surface roughness characterization of AA7075/ 10 wt.% SiC composite.