Influence of Single and Double Stage Forging on Cutting Forces of Al 7075/BSF Metal Matrix Composites

In the present study, an attempt has been made to investigate the influence of the forging parameters on cutting forces for different cutting speed, depth of cut, and feed rate during machining of Al 7075 alloy and Al 7075 alloy with short basalt fiber reinforced metal matrix composites. The experiments were conducted by using a lathe machine with tool dynamometer setup. Keyword- Forging effect, Metal Matrix Composites, stir casting, tangential force, SEM I. INTRODUCTION Metal matrix composites are produced by combination of metal matrix and stiff and hard reinforcing phase. Incorporation of reinforcements enhances the properties like adhesive, abrasive, diffusion wear resistance, thermal properties, hardness, and stiffness. The mechanical properties can be fine tuned to the requirement by choosing the size, shape, and distribution of reinforcement. In the last decades, Al metal matrix composites have been increasingly used in the aerospace industry and advanced arm systems such as satellite bearing, inertia navigation system, and laser reflector. Al metal matrix composites (AMMCs) are most commonly manufactured by a stir-casting technique or powder metallurgy technique (1). Stir casting is the simplest and the most commercial technique. The development of MMCs by stir casting technology has been one of the unique and feasible processes because of producing better matrix particle bonding, easier control of matrix structure, simplicity, higher production rate, and low cost (2). It involves stirring the melt along with reinforcement's s and then allowing the mixture to solidify. Due to the addition of reinforcing materials, which are normally harder and stiffer than matrix, machining becomes significantly more difficult than those of conventional materials (3). The study the influence of cutting parameters on machinability of Al 7075 alloy and Al 7075 alloy/basalt short fiber in turning operation using coated cemented carbide tools for all three conditions like as cast, single forged and double forged has been carried out. Cutting parameters are important both from a design and process planning perspective. Concerning the cutting parameters, cutting speed, depth of cut and feed are the three most relevant factors to be consider, since they directly affect the machining forces, and also because they can be relatively changed. Cutting width is more related to the component configuration and the selected tool geometry.