Optimization of hybrid al alloy machining with integration of temperature sensor and dynamometer

This study investigates the optimization of machining performance for aluminum metal matrix composites (Al-MMC) through real-time monitoring using temperature sensors and a dynamometer. It evaluates the impact of temperature and cutting forces on tool performance, comparing coated and uncoated inserts. Results reveal that higher feed rates correlate with increased cutting forces, affecting tool temperature. The dynamic interaction of spindle speed, temperature, and cutting forces is analysed across 6%, 9%, and 12% ZrB2-alloyed aluminum alloys (6063, 6082, and 7075) with both insert types. Material-specific behaviors highlight the crucial role of spindle speed; for instance, uncoated inserts in 6% ZrB2 Aluminum 6063 show a temperature peak of 40 °C at 180 RPM, coinciding with a cutting force of 11.236 kgf. Coated inserts exhibit improved performance, as seen in 12% ZrB2 Aluminum 6063, with temperature peaking at 38 °C at 280 RPM, aligning with a cutting force peak of 14.483 kgf at 180 RPM. These findings emphasize tailored parameter adjustments for optimal efficiency in precision machining processes, offering valuable insights for industries utilizing Al-MMC materials to enhance machining efficiency and quality.