Optimization of Dry Machining for Beryllium-Modified Hypereutectic Al-Si Alloys Using Ceramic Tools: A Taguchi Approach

This project investigates the Machining Behavior of Hypereutectic Aluminum-Silicon Alloys Modified with Beryllium (Be), focusing on the effects of varying machining parameters and tool geometries using ceramic tools. Hypereutectic Al-Si alloys are widely used in automotive and aerospace applications due to their high strength, wear resistance, and lightweight properties. However, their high Silicon content makes them difficult to machine, leading to rapid tool wear and challenges in achieving a high-quality surface finish. The addition of Beryllium is expected to refine the microstructure, reduce the size of silicon particles, and improve machinability. This study aims to optimize machining parameters such as main cutting forces, surface roughness, and power consumption while evaluating the performance of ceramic tools with different geometries. Preliminary experiments involve stir casting of the modified alloy and preparing it for CNC machining. The results will have significant industrial applications, particularly in high-performance sectors where the balance between material properties and machinability is critical. The study also indicated the impact of input parameters such as feed rate, cutting and depth of cut over the factors such as cutting force, surface roughness and power consumption.