Journal of Science and Technology of Composites

Journal of Science and Technology of Composites

An Experimental Study on the Effect of Tin on Tool Wear Control and Machining Parameter Optimization in Turning of Aluminum Composite

Document Type : Research Paper

Authors
Mohammad Hasanifard 1
Reza Azarafza 2
Mohammad Hossein Alaei 3
Moslem Najafi 3
1 PhD Student, Faculty of Materials & Manufacturing Technologies, Malek Ashtar University of Technology, Tehran, Iran.
2 Associate Professor, Faculty of Materials & Manufacturing Technologies, Malek Ashtar University of Technology, Tehran, Iran.
3 Assistant Professor, Faculty of Materials & Manufacturing Technologies, Malek Ashtar University of Technology, Tehran, Iran.
10.22068/jstc.2025.2065172.1925
Abstract
Aluminum matrix composites reinforced with Mg₂Si particles are considered advanced engineering materials due to their desirable mechanical and thermal properties, such as high specific strength and hardness. However, machining these composites is often accompanied by challenges such as severe tool wear, mainly due to the presence of hard and brittle phases. In this study, the effects of machining parameters and tin (Sn) additive on tool wear behavior during the turning of Al–Mg₂Si composites were experimentally and statistically investigated. Two types of composites—one without additive and the other containing 1 wt.% Sn—were fabricated using the in-situ casting method. Machining tests were performed under four levels of cutting speed, feed rate, and depth of cut, and in both dry and wet conditions, based on the Taguchi design with an L16 orthogonal array. Tool wear was evaluated in terms of wear morphology and wear area using a scanning electron microscope (SEM) and ImageJ software. The results indicated that adhesive wear was the dominant mechanism in both composites, and the addition of Sn significantly reduced tool wear. Taguchi analysis and multiple regression modeling revealed that depth of cut had the most significant effect on tool wear. The optimal machining condition was identified as a 0.5 mm depth of cut, 0.08 mm/rev feed rate, 710 rpm spindle speed, and wet cutting. Additionally, an alternative condition with 1 mm depth of cut and 0.12 mm/rev feed rate was suggested for improved productivity.
Keywords
Tool wear
Aluminum matrix composite
Turning
Tin
Mg2Si

Subjects

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Journal of Science and Technology of Composites
Volume 12, Issue 1
Summer 2025
Pages 2717-2727