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Precision machining of an aluminum alloy piston reinforced with a cast iron insert

  • Uthayakumar, Marimuthu1
  • Prabhakaran, Gopalakrishnan2
  • Aravindan, Sivanandham3
  • Sivaprasad, Jonna Venkata4
  • 1 Kalasalingam University, Department of Mechanical Engineering, Krishnan Koil, Tamil Nadu, 626-190, India , Krishnan Koil, Tamil Nadu (India)
  • 2 Caledonian College of Engineering, Department of Mechanical and Industrial Engineering, C.P.O Seeb - 111, Sultanate of Oman , C.P.O Seeb - 111 (Oman)
  • 3 Indian Institute of Technology, Department of Mechanical Engineering, New Delhi, 110-016, India , New Delhi (India)
  • 4 India Pistons Ltd, Engineering Department, Maraimalai Nagar, Chennai, 603-209, India , Maraimalai Nagar, Chennai (India)
Published Article
International Journal of Precision Engineering and Manufacturing
Korean Society for Precision Engineering
Publication Date
Jan 01, 2009
DOI: 10.1007/s12541-009-0002-7
Springer Nature


Bimetallic pistons consisting of aluminum alloy reinforced with a cast iron (CI) insert are used to reduce the weight and improve the wear resistance of pistons. A major problem with machining such bimetallic pistons is producing the desired shape with minimal cutting forces and without damaging the bonding registry. The objective of this paper is to determine the optimal cutting parameters (cutting speed, feed, and depth of cut) for turning bimetallic pistons. When machining, we wish to obtain optimal values of the cutting forces and a better surface integrity while maintaining the required surface finish. Experiments were conducted following Taguchi’s parameter design approach using a cubic boron nitride tool for the machining. The results indicate that the process parameters affected the mean and variance of the cutting force at the Al-CI interface of the piston. The Al-CI interface was examined using an ultrasonic piston bond tester after machining to assure the bond quality. The surface roughness of the components was measured with a surface roughness tester. A mathematical model was developed using the Systat 12.0 software package to establish the relationship between the input quantities (speed, feed, and depth of cut) and the output data (cutting force). The output data of the mathematical model were compared with the experimental results. The results from the Taguchi robust design concept were compared with the results obtained from a nonconventional Genetic Algorithm optimization technique.

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