Optimisation of Drilling Parameters of Sicp Reinforced Al-2024 Composite used in Aircraft Industry

Abstract

In this research, the machinability characteristics of Al-2024 + SiC composite materials produced via the stir casting method were experimentally analyzed. The test samples included unreinforced composites and those with 5%, 10%, and 15% SiC particle reinforcement. Microstructural examinations were conducted using optical and Scanning Electron Microscopes (SEM). Hardness measurements were taken using the Brinell scale. Machinability tests involved drilling on a 3-axis CNC machine with both HSS and HSS + TiN drill bits, using three different feed rates and cutting speeds. The unreinforced sample exhibited the lowest hardness, while the sample with 15% SiC reinforcement showed the highest hardness. The HSS + TiN drill bit outperformed the HSS drill bit. Thrust force and torque values increased with higher feed rates and cutting speeds. ANOVA statistical analysis indicated that the drill type (variable A) influenced thrust force by 58.36%, the composite type (variable D) by 31.25%, and cutting speed (variable C) by 7.64%. For torque, the composite type (variable D) had a 55.94% influence, the drill type (variable A) 24.96%, and cutting speed (variable C) 13.26%. It was also found that the interaction between variables A and B did not affect cutting forces.