End mill studies on Al6061 hybrid composite prepared by ultrasonic-assisted stir casting

To produce the lightweight material for the high payload with excellent strength in particular for defense applications, reinforcements were introduced into the aluminum to form a hybrid composite. SiO2 was extracted through suitable techniques from rice husk ash particles. Through the ultrasonic probe sonication stir-casting process, the standard composition of 3% SiO2 was added along with varying weight percentages (3, 6, 9, and 12) of TiC particles as reinforcement in Al 6061 matrix. The machinability of the fabricated hybrid composite was evaluated through end face milling with varied machining parameters such as spindle speed, feed rate, and depth of cut. The output performance measurable characteristics were temperature and Ra. Thermal energy generated during the machining conditions was studied through the thermal image FLIR camera. From the machining conditions, machining level with SS of 1000, FR of 100, and DOC of 0.2 lead to having the highest temperature of 119 degrees C. The working temperature for the N2 sample was recorded to be 17% higher with an increase of 3% of TiC. The impact of wt% of reinforcements and governing parameters on tool wear was analyzed by SEM images. The addition of RHA and TiC reinforcements leads to raising cutting zone temperature, tool wear, and Ra. The thermal distortion effect on tool wear, chip morphology, and the surface profile of the samples were discussed and reported.