Mechanical Characterization and Machinability Optimization of Stir-Cast Al6061–SiC Metal Matrix Composites

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Year : 2026 | Volume : 14 | 03 | Page :
    By

    B. Suresh Kumar Reddy,

  • B. Subba Rao,

  • PVR Girish Kumar,

  • S. Gajanana,

  • B. Ravi Kumar,

  1. Associate Professor, Department of Mechanical Engineering, MVSR Engineering College, Hyderabad, Telangana, India
  2. Associate Professor, Department of Mechanical Engineering, MCEME CTW Engineering College, Secunderabad, Telangana, India
  3. Associate Professor, Department of Mechanical Engineering, Geethanjali College of Engineering, Hyderabad, Telangana, India
  4. Professor, Department of Mechanical Engineering, MVSR Engineering College, Hyderabad, Telangana, India
  5. Associate Professor, Department of Mechanical Engineering, MVSR Engineering College, Hyderabad, Telangana, India

Abstract

This study presents the fabrication, mechanical characterization, metallurgical analysis, and machinability optimization of Aluminum 6061 reinforced with Silicon Carbide (SiC) metal matrix composites (MMCs) at three weight fractions: 5%, 7.5%, and 10%. Composites were manufactured using the stir casting technique, followed by comprehensive mechanical testing (tensile, hardness, and impact), optical microscopy, and scanning electron microscopy (SEM). Machinability was assessed through turning experiments on a lathe using an L9 Taguchi orthogonal array. Four process parameters viz., cutting speed (414–640 rpm), feed rate (0.061–0.243 mm/rev), depth of cut (0.5–0.9 mm), and back rake angle (10°–20°), were systematically varied to measure resultant cutting forces. Regression models were developed using Minitab to correlate process parameters with cutting force response. Results indicate that Al6061-7.5% SiC exhibits superior mechanical properties: tensile strength of 137.44 N/mm², yield strength of 87.73 N/mm², elongation of 6.18%, and Brinell hardness of 64 BHN. Feed rate was found to be the dominant factor influencing cutting forces, contributing over 61% of the total variance. Finite element simulation of tensile specimens using Autodesk Fusion 360 validated experimental results with maximum stress of 171.2 MPa at 7.5% SiC loading. The developed regression equations facilitate accurate prediction of cutting forces, enabling selection of optimum machining conditions for Al6061-SiC composites.

Keywords: Metal Matrix Composites; Aluminum 6061; Silicon Carbide; Stir Casting; Taguchi Method; Machinability; Cutting Force; Regression Analysis; Finite Element Analysis.

How to cite this article:
B. Suresh Kumar Reddy, B. Subba Rao, PVR Girish Kumar, S. Gajanana, B. Ravi Kumar. Mechanical Characterization and Machinability Optimization of Stir-Cast Al6061–SiC Metal Matrix Composites. Journal of Polymer & Composites. 2026; 14(03):-.
How to cite this URL:
B. Suresh Kumar Reddy, B. Subba Rao, PVR Girish Kumar, S. Gajanana, B. Ravi Kumar. Mechanical Characterization and Machinability Optimization of Stir-Cast Al6061–SiC Metal Matrix Composites. Journal of Polymer & Composites. 2026; 14(03):-. Available from: https://journals.stmjournals.com/jopc/article=2026/view=245556


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Ahead of Print Subscription Original Research
Volume 14
03
Received 28/04/2026
Accepted 02/05/2026
Published 30/05/2026
Publication Time 32 Days
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