Tool performance optimization while machining aluminium-based metal matrix composite

Finite element (FE) models and the multi objective genetic algorithm (MOGA-II) have been applied for tool performance optimization while machining aluminum-based metal matrix composites. The developed and verified FE models are utilized to generate data for the full factorial design of experiment (DOE) plan. The FE models consist of a heterogenous workpiece, which assumes uniform distribution of reinforced particles according to size and volume fraction. Cutting forces, chip morphology, temperature contours, stress distributions in the workpiece and tool by altering cutting speed, feed rate, and reinforcement particle size can be estimated using developed FE models. The DOE data are then utilized to develop response surfaces using radial basis functions. To reduce computational time, these response surfaces are used as solver for optimization runs using MOGA-II. Tool performance has been optimized with regard to cutting temperatures and stresses while setting a limit on specific cutting energy. Optimal solutions are found with low cutting speed and moderate feed rates for each particle size metal matrix composite (MMC).