Title: Effects of different cutting conditions on the surface roughness parameters of iron-copper-carbon powder metallurgy composites

Authors: Miklós Czampa; István Biro; Tibor Szalay

Addresses: Department of Manufacturing Sciences and Engineering, Budapest University of Technology and Economics, H-1111 Budapest, Muegyetem emb.3, Budapest, Hungary ' Department of Manufacturing Sciences and Engineering, Budapest University of Technology and Economics, H-1111 Budapest, Muegyetem emb.3, Budapest, Hungary ' Department of Manufacturing Sciences and Engineering, Budapest University of Technology and Economics, H-1111 Budapest, Muegyetem emb.3, Budapest, Hungary

Abstract: Metal matrix composites gained higher importance in the last decades. Due to the porous structure and the wide range of material compositions, the secondary machining of these materials poses several difficulties for the manufacturers. In this work, the effect of cutting parameters such as cutting speed, feed rate, depth of cut, directions of cut and different cooling types were investigated during the face milling of iron-based sintered metals made by powder metallurgy. A full factorial design was selected for the reliable experiments. Main effect analyses have been carried out to know the significance of the input parameters. Surface roughness parameters (Ra and Rz) were selected as response parameters. The applicability of simple models for predicting the surface roughness parameters based on the measured data were also investigated. The investigations revealed that dry machining conditions and high cutting speeds resulted in better surface roughness values.

Keywords: metal matrix composites; 1.1191 steel; face milling; cutting conditions; surface roughness; dry machining; cold air cooling; full factorial experimental design; surface roughness models.

DOI: 10.1504/IJMMM.2017.087617

International Journal of Machining and Machinability of Materials, 2017 Vol.19 No.5, pp.440 - 456

Received: 07 Nov 2016
Accepted: 19 Jan 2017

Published online: 20 Oct 2017 *

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