On the impacts of cutting parameters on surface roughness, tool wear mode and size in slot milling of A356 metal matrix composites reinforced with silicon carbide elements (original) (raw)
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Machinability of a silicon carbide reinforced aluminium metal matrix composite
Wear, 1995
The machinability of a DURALCAN® aluminium metal matrix composite (A359/SiC/20p) has been studied in this paper. Continuous turning of round composite bars using tools with 25 mm polycrystalline diamond (PCD) inserts has been selected as the test method. The matrix of test conditions included cutting speeds of 300, 500 and 700 m min−1 and feed rates of 0.1, 0.2 and 0.4 mm rev−1 while the depth of cut has been kept constant at 0.5 mm.The performance of the tools is based on development of 0.25 mm maximum flank wear, which has been monitored by optical and scanning electron microscopy. The tool life data have been analyzed using regression techniques and a general form of the Taylor equation has been developed to describe the tool performance on this composite. The time required to reach the tool wear limit decreased with increases of speed and feed. However, the volume of material removed before reaching the wear limit actually increases with the higher feed rate. These phenomena have been reconciled by rewriting the Taylor equation in a modified form. Practical implications of this deviation are discussed and comments are made on the effects of cutting parameters on surface finish and chip formation.
Machining of aluminium based metal matrix composites
Applied Composite Materials, 1995
The machining of aluminium 2618 particulate reinforced Metal Matrix Composite (MMC) with 18 vol. % silicon carbide (SiC) using cemented carbide cutting tools has been undertaken. Two grades of cemented carbide inserts, uncoated K68 grade and coated KC910 grade (coated with TiC and A1203) having negative and positive rake angles (with and without chip breaker) have been used to machine this material in order to understand the machining process, tool failure modes and wear mechanisms. Turning tests in the speed range 15-10 m/min have been carried out at 0.2,0.4 and 0.6 mm/rev feed rates and 2 mm and 4 mm depths of cut. IR Pashby, Senior Lecturer, Department of Engineering, University of Warwick for his magnificent supervision, guidance, continuous encouragement and many valuable discussions which led to the successful completion of this work. The author is also grateful to Dr S Barnes for his valuable help, contribution and discussions throughout the development of this work. Additional thanks should go to the technical staff that have contributed to this work in term of help and time spent on the practical work, particularly Mr MA Robinson, Mr S Fox, Mr G Booth and Mrs V Kading for her assistance on the SEM and Mr GC Canham for the photographic aspect of this project.
Study of cutting force and surface roughness in milling of Al/Sic metal matrix composites
Scientific Research and …, 2011
In this experimental study, composite samples containing silicon are produced with powder metallurgy technique by sintering under argon atmosphere. The effect of cutting speeds, feed rates and different cutting tool types on cutting forces and surface roughness are investigated in the face milling operation of silicon carbide particle reinforced aluminium metal matrix composites. Machining operations are conducted using coated and uncoated tools. Main cutting force (F x) and surface roughness (Ra) are measured for at four different cutting speeds (300, 350, 400 and 450 m/min) and three different feed rates (0.1, 0.15, 0.20 mm/tooth) and two depth of cut (0.5, 1 mm). As a result of experimental evaluation for coated and uncoated tools, main cutting force increased with increasing feed rate and depth of cut whereas, it is decreased significantly by higher cutting speed. On the other hand, Al-SiC produces the worst surface finish with increasing feed rate and depth of cut in the uncoated tools whereas, the surface roughness in the coated tools are decreased under the same cutting conditions. The best surface roughness is obtained with increasing cutting speed for both uncoated and coated tools.
Journal of Materials Processing Technology, 2005
Metal matrix composites (MMC) have become a large leading material in composite materials and particle reinforced aluminium MMCs have received considerable attention due to their excellent engineering properties. These materials are known as the difficult-to-machine materials, because of the hardness and abrasive nature of reinforcement element like silicon carbide (SiC) particles. In this study, homogenised 5% SiC-p aluminium MMC material was selected for experimental investigation of tool wear and surface roughness. Two types of K10 cutting tool (uncoated and TiN-coated) were used at different cutting speeds (50, 100 and 150 m/min), feed rates (0.1, 0.2 and 0.3 mm/rev) and depths of cut (0.5, 1 and 1.5 mm). In dry turning condition, tool wear was mainly affected by cutting speed, increased with increasing cutting speed. Tool wear was lower when coated cutting tool was used in comparison to uncoated one. Surface roughness influenced with cutting speed and feed rate. Higher cutting speeds and lower feed rates produced better surface quality.
This paper presents the study of the tool wear mechanism in machining the metal matrix composites (MMC) and its dependence on the percentage of reinforcing with MMC. Aluminum alloy (A356-SiC) silicon carbide metal matrix composite of two samples, were prepared in-house by using stir casting method. Samples having 10 and 20% silicon carbide particles (grain size ranging from 55 to 85 µ µ µ µm) by weight are fabricated in the form of cylindrical bars. Experiments were conducted in the medium duty lathe by using polycrystalline diamond (PCD) insert. Optimum parameters were obtained by analyzing the power consumed on an average surface roughness (Ra) of the machined component. By setting these optimum parameters at a constant machining condition, tool wear study was carried out for a time duration of 100 min. The result showed that the tool flank wears was maximum while machining 20% of the SiC reinforcing MMC when compared with 10% of the SiC reinforcing MMC. The result proved that the influence of SiC particles' weight percentage was a dependent parameter on tool wear. The main mechanism of tool wear in machining Al-SiC MMC includes two-body abrasion and three-body abrasion. However, the tool wear images were captured by optical microscope and SEM, which supported the result.
The International Journal of Advanced Manufacturing Technology, 2010
Metal matrix composites (MMC) have become a leading material among composite materials, and in particular, particle reinforced aluminum MMCs have received considerable attention due to their excellent engineering properties. These materials are known as the difficult-to-machine materials because of the hardness and abrasive nature of reinforcement element-like silicon carbide particles (SiC p). In this study, an attempt has been made to model the machinability evaluation through the response surface methodology in machining of homogenized 20% SiC p LM25 Al MMC manufactured through stir cast route. The combined effects of four machining parameters including cutting speed (s), feed rate (f), depth of cut (d), and machining time (t) on the basis of two performance characteristics of flank wear (VB max) and surface roughness (Ra) were investigated. The contour plots were generated to study the effect of process parameters as well as their interactions. The process parameters are optimized using desirability-based approach response surface methodology.
Machining of Al/SiC particulate metal-matrix composites: Part I: Tool performance
Journal of Materials Processing Technology, 1998
A robust 3-D ®nite element model of a cutting tool is presented in this paper. The model takes into consideration the thermal and mechanical interactions at the tool/chip and tool/workpiece interfaces. Temperature-dependant material properties are incorporated in the model. The model was applied to the special case of the turning of Al/SiC particulate metal matrix composites, where high tool wear rates represent a challenge to the industry. The temperatures and stresses predicted by the model are in agreement with experimental measurements and tool wear observations. The wear patterns predicted by the model include crater wear, tool pitting and tool chipping. Thus, the model presented could be utilized in the selection of the tool material, geometry and cutting parameters that would result in the least tool wear, and hence helps to reduce machining costs and tool change down-time. Controlling tool wear is expected to enhance the surface integrity of the workpiece. #
Evaluation of tool wear in high-speed face milling of Al/SiC metal matrix composites
Journal of the Brazilian Society of Mechanical Sciences and Engineering, 2019
In recent years, a new generation of composite materials has been introduced as metal matrix composites (MMCs) in order to simultaneously provide higher strength and stiffness. Industrial interests resulted in deep investigations and researches on machinability of MMCs and especially in the field of high-speed machining. High-speed machining processes offer a higher machining efficiency and reduced cost of the process, which made them the process of interest in many manufacturing industries. However, matrix reinforcement by addition of hard particle phases to the MMCs significantly increases machining difficulty, tool wear, surface quality deterioration and overall fabrication costs. In the current research, the cutting speed, feed rate, depth of cut, presence of cryogenic coolant and their effect on the tool wear of high-speed machining of Al/SiC MMC reinforced with 15 wt% SiC particles have been investigated. The results have shown that silicon carbide particles in the aluminum matrix cause a severe tool wear. However, the severity of tool wear has decreased by applying a cryogenic cooling.
Machining Performance of 7075 Al Alloy SiC Metal Matrix Composite with HSS and Carbide Tool
Metal matrix composites (MMC) have received considerable attention due to their excellent engineering properties. These materials are difficult to machine because of hardness and abrasive nature of reinforcement particles like silicon carbide. This Paper presents experimental work from a series of turning test in which high speed steel (HSS) and carbide tools were used to machine 7075 aluminium alloy 10 %SiC-metal matrix composite. The influence of machining parameters, e.g., cutting speed, feed and depth of cut on the surface roughness, cutting force(thrust force, feed force and radial force), tool wear and tool life were investigated. The results indicate that tool life of carbide tool is 55% more as compared to HSS tool. HSS tools suffered from excessive edge chipping and crater wear during the machining of the metal-matrix composite. It was found that the carbide tool is able to resist wear better than HSS tool in cutting speed range from 40 to 100 m/min and feed range from 0.1 to 0.8 mm/rev. The value of cutting force is constant in the cutting speed range of 60 to 100 m/min while using HSS tool and in the cutting speed range of 40 to 100 m/min when machining with carbide tool. Surface roughness is minimum at cutting speed of 100 m/min, feed of 0.1 mm/ rev and depth of cut of 0.02mm both for AA7075 and AA7075/ 10 %Si composite.
Evaluation of tool wear when machining SiCp-reinforced Al-2014 alloy matrix composites
Materials & Design, 2004
SiC p -reinforced metal matrix composites (MMCs) containing two levels of SiC particles (8 and 16 wt%) of different mean particle sizes 30, 45 and 110 lm were prepared using a melt stirring-squeeze casting route. Machining tests were carried out on the composites using uncoated and triple-layer coated carbide cutting tools at various cutting speeds under a constant feed rate and depth of cut. The effects of cutting speed and coating of tool on tool wear were investigated. Furthermore, surface roughness measurements were carried out on the machined surfaces. The reinforcement particle size and its weight fraction together with the cutting speed were found to be the major factors affecting the tool wear. Coated carbide cutting tools performed better than uncoated carbide cutting tools for all the materials machined in terms of tool wear. However, uncoated cutting tools produced better surface finish in terms of mean R a values, particularly at lower cutting speeds. Although the tool wear mechanism remained one of abrasion, detailed examination of the cutting edges under scanning electron microscope (SEM) showed that higher cutting speeds led to edge chipping.