Tribological and machining characteristics of milling SiCp/Al MMC composites under sustainable cooling conditions

SiC particle-based aluminum matrix (SiCp/Al 20%) is characterized by poor surface quality, high cutting forces, and accelerated tool wear during machining. Environmentally friendly cooling/lubrication (CO2 snow, MQL) can advance the machinability of such composites even at high material removal rates. In this experimental study, milling of SiCp/Al was performed by implementing MQL and CO2 at different cutting speeds and feed per tooth and compared the effect of these lubri-cooling against dry cutting. The experimental results showed the minimum cutting forces, surface roughness, and tool life under MQL followed by CO2 and dry cutting. The microscopic analysis depicted adhesion and abrasion as prevalent wear mechanisms. The EDS analysis (line, point, mapping) revealed relatively less adhesion of aluminum (Al) and silicon (Si) chemical elements under cryogenic compared to dry cutting on tool major cutting edge. Besides, the chip analysis under MQL machining showed discontinuous and serrated-type chips.