Experimental Investigation of Spindle Speed and Feed Influence on Cylindricity Tolerance While Drilling Aluminum6061 MMC Filler with 15% Weight Percentage of B4C and in Comparison with Cast Aluminum6061

The aim of this study is to evaluate the average cylindricity tolerance of Al6061 cast to that of metal matrix composites (MMCs) with varying weight ratios of boron carbide (B4C), namely 15% of B4C. This study used a 10-mm thick Al-B4C MMC plate with dimensions of 150 × 150 mm. Al-B4C MMC composites were made with various B4C weight fractions (15%) using the stir casting process. The B4C reinforcements were heated to 650 °C before being stir cast at 800 °C. The ASTM standard was used to test the cylindricity tolerance. Each plate in the variable set (15% weights of B4C/Aluminium MMC) and, in comparison, with cast Al6061, 13 test samples for each set have been performed in this study. We have found that incorporating 15% B4C into the composition of the 6061 alloy leads to marked enhancements in dimensional precision compared to the original as-cast 6061 alloy. Particularly, the tolerance for hole sphericity is significantly diminished to 0.095 mm with the B4C-infused alloy, a substantial improvement from the larger tolerance of 2.134 mm. Higher B4C reinforcement has resulted in improvements in mechanical and physical characteristics, with 15% weight of B4C reinforcement resulting in a significant increase in the qualities of Al-B4C metal matrix composites.