Investigation into effect of silicon morphology on surface roughness while machining Al-Si-Cu-Mg alloy

Surface roughness is one of the key measures in manufacturing that describes machined surface integrity. In this research work, the effect of silicon morphology on surface roughness when turning Al-11%Si-1.8%Cu alloy and Sr-containing alloys was investigated. The experiments are carried out under oblique dry cutting conditions using a PVD TIN-coated insert at three cutting speeds of 70, 130 and 250 m/min, feed rates of 0.05, 0.1, 0.15 mm/rev, and 0.05 mm constant depth of cut. The result released that surface roughness decreased with adding 0.04 wt.% Sr to casting. The surface roughness values reduce with cutting speed increment from 70 m/min to 250 m/min. Also, the surface finish deteriorated with increase in feed rate from 0.5 mm/rev to 0.15 mm/rev.