Machinability and Reliability Analysis of Al6063–Al2O3 Metal Matrix Composites Using Image-Based Flank Wear Evaluation

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Year : 2026 | Volume : 14 | 02 | Page :
    By

    K. Usha,

  • S. Gajanana,

  • Pranav Ravindrannair,

  1. Professor, Department of Electronics and Communication Engineering, MVSR Engineering College, Hyderabad, Telangana, India
  2. Professor, Department of Mechanical Engineering, MVSR Engineering College, Hyderabad, Telangana, India
  3. Assistant Professor, Department of Automobile Engineering, MVSR Engineering College, Hyderabad, Telangana, India

Abstract

This study explores the machinability and reliability characteristics of Al6063–Al2O3 metal matrix composites (MMCs) as analogues for polymer–metal hybrid composite systems, focusing on their potential use in lightweight structural and metal matrix composite-integrated applications. The composite specimens were fabricated through stir casting with 3% and 9% Al2O3 reinforcements, followed by mechanical characterization that confirmed significant enhancements in hardness and strength compared to unreinforced Al6063. Machining experiments were performed using a high-speed steel (HSS) single-point cutting tool on a conventional lathe, applying the Taguchi design of experiments with five control factors—cutting speed, feed rate, depth of cut, rake angle, and reinforcement content, each varied at two levels. The material removal rate (MRR) and flank wear were quantitatively analyzed, with the latter evaluated using MATLAB-based image processing techniques to assess wear morphology and interface degradation. Results revealed that higher speeds and feeds yielded improved MRR, whereas lower cutting conditions promoted tool reliability by minimizing flank wear. These outcomes establish a correlation between machining reliability and reinforcement fraction, reflecting behavior similar to polymer matrix composites under tribo-mechanical stress. The study provides valuable insights for extending machinability optimization and surface integrity control to hybrid metal matrix composite structures used in aerospace and automotive manufacturing.

Keywords: HSS, single point cutting tool, image processing, Taguchi DoE, Reliability.

How to cite this article:
K. Usha, S. Gajanana, Pranav Ravindrannair. Machinability and Reliability Analysis of Al6063–Al2O3 Metal Matrix Composites Using Image-Based Flank Wear Evaluation. Journal of Polymer & Composites. 2026; 14(02):-.
How to cite this URL:
K. Usha, S. Gajanana, Pranav Ravindrannair. Machinability and Reliability Analysis of Al6063–Al2O3 Metal Matrix Composites Using Image-Based Flank Wear Evaluation. Journal of Polymer & Composites. 2026; 14(02):-. Available from: https://journals.stmjournals.com/jopc/article=2026/view=239594


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Ahead of Print Subscription Original Research
Volume 14
02
Received 08/11/2025
Accepted 20/11/2025
Published 02/04/2026
Publication Time 145 Days
31

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