Exploring energy aspects and tool wear on dry turning of cupola slag-reinforced aluminium metal matrix composites

This study investigates the dry turning of cupola slag reinforced aluminium metal matrix composites (AMCs) with the aim of exploring the energy aspects and tool wear. The study involves the fabrication of cast cupola slag reinforced Al–4.5–Cu matrix composites by the economic stir casting method with varying the weight percentage of cupola slag (3 wt.%, 5 wt.% and 7 wt.%) followed by dry turning using coated carbide tool. The experimentation involves process input parameters such as spindle speed, feed rate and weight percentage of slag and the experimentation has been designed using statistical full factorial methodology. The energy aspects have been evaluated by measuring cutting force and power consumed during machining and tool wear have been measured using optical microscopy. The results showed that the cutting force and power consumption increase with increasing speed and feed rate decreases with increasing slag concentration. Slag incorporation has a significant effect on machinability as it eases the turning process when compared with base alloy. Moreover, detailed analyses of the effect of process input on the responses have been studied along with rigorous comparison of machining quality. The findings can be useful in optimizing the cutting conditions for improved energy efficiency and tool life in the machining of similar materials.