The use of metal-based composite materials, especially aluminum composites, has found wide applications in various industries such as automotive, aerospace, military, etc., due to their favorable mechanical properties, high strength-to-weight ratio, and high wear resistance and hardness. On the other hand, these mechanical properties and high hardness and wear resistance, which is due to the presence of reinforcing particles such as silicon carbide in these composites, makes them difficult to machine, so that only special tools and blades, such as polycrystalline diamond tools, can machine these composites optimally. The findings from this study can be valuable in optimizing the turning process of aluminum-based metal matrix composites.

In this study, the effects of four input parameters - cutting speed, feed rate, feed force in the X direction, and feed force in the Z direction - on the output parameter of tool wear rate in the dry turning process of A359 aluminum alloy metal matrix composite reinforced with 20 vol.% of silicon carbide particles using polycrystalline diamond tools were investigated.

The numerical investigation of the effect of each of the four input parameters on the output parameter was done using the E-fast statistical sensitivity analysis method, which has high speed in quantitative and qualitative data analysis. The results showed that the parameters of feed force in X direction, feed rate, feed force in Z direction, and cutting speed have 88%, 8%, 3%, and 1% effect on tool wear, respectively.