Optimizing Coating Thickness and Tool Geometry in Turning Nano Hybrid Aluminium Composite

This study employs a numerical model of the turning procedure and optimized for ideal coating thickness and tool geometry during the machining of aluminium composites. Tungsten carbide (WC) is coated with aluminium oxide (Al2O3) ceramic and considered for machining aluminium alloy 6061 reinforced with silicon carbide and multiwalled carbon nanotube (AA6061+15%SiC+3%MWCNT) reinforced composite by wt.%. Three coating thicknesses (5, 10, and 15 µm) were considered with relief angle (2, 4, and 6°), and nose edge radius (0.4, 0.6, and 0.8 mm). An orthogonal array developed by Taguchi (L9) served as the basis for the experiments, and the output responses, temperature at interface (IT), and resultant cutting forces (RCF) were optimized using signal-to-noise ratio. Observation shows that the RCF and IF tend to lower with lower coating thickness. In contrast, a moderate 4° relief angle and lower (0.4 mm) nose radius deliver lower RCF and lesser IT