Analysis of two-and three-body abrasive wear during machining of aluminium-based metal matrix composite (original) (raw)
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Tool wear in turning ceramic reinforced aluminum matrix composites-A review
Cutting tool wear during turning of ceramic reinforced aluminum matrix composites was reviewed. Though tools of different materials, such as tungsten carbide, coated tungsten carbide, ceramics, cubic boron nitride, polycrystalline cubic boron nitride, chemical vapor deposition diamond coated tungsten carbide, and polycrystalline diamond were used for turning the aluminum matrix composites, better performance of polycrystalline diamond tools was observed in terms of tool life. The results obtained by many researchers indicated that dominant tool wear mechanism was abrasion, and tool life was mainly affected by flank wear during turning of these composites. The flank wear increased on increasing particulate size or weight fraction of reinforcement. Flank wear of the cutting tool also increased with increasing cutting speed, feed, and depth of cut; however, cutting speed was the most significant parameter affecting flank wear, followed by feed. Influence of depth of cut on flank wear was limited or insignificant.
Procedia Engineering, 2013
Metal matrix compositions (MMC) have become a leading materials and particles reinforced aluminum MMCs have received considerable attention due to their excellent mechanical properties like high hardness, high tensile strength etc. These materials difficult to machine because of high hardness and abrasive nature of reinforcing elements like alumina particles. In this study, homogenized (2%, 4%, and 6%) by weight of alumina aluminum metal matrix composite materials were fabricated and selected as workpiece for experimental investigations of tool wear, surface roughness and metal removal rate. The titanium nitride coated tungsten carbide tool and uncoated tungsten carbide tools were used at different cutting speeds (265,400,535 rpm), feed rate (0.29, 0.32, 0.35 mm/rev.), and depth of cut (1.0, 1.5, 2.0 mm). The microstructures and mechanical properties of produced composite specimens have been investigated. It has been observed that increase of reinforcement element produced better mechanical properties such as hardness and tensile strength. The turning experiments were planned by taguchi method. The obtained experimental data has been analyzed using signal to noise ratio and ANOVA. The main effects have been discussed and percentage contribution of various process parameters speed, feed, depth of cut and concentration effecting tool wear, surface roughness and metal removal rate have been determined. .
Metals
Metal-matrix composites (MMCs) are made of non-metallic reinforcements in metal matrixes, which have excellent hardness, corrosion, and wear resistance. They are also lightweight and may pose a higher strength-to-weight ratio as compared to commercial titanium alloys. One of the MMCs with remarkable mechanical properties are titanium metal matrix composites (Ti-MMCs), which are considered a replacement for super-alloys in many industrial products and industries. Limited machining and machinability studies of Ti-MMCs were reported under different cutting and lubrication conditions. Tool wear morphology and life are among the main machinability attributes with limited attention. Therefore, this study presents the effects of cutting and lubrication conditions on wear morphology in carbide inserts when turning Ti-MMCs. To that end, maximum flank wear (VB) and cutting forces were recorded, and the wear morphologies within the initial period of the cut, as well as the worn condition, were...
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.
A STUDY ON 3-BODY ABRASIVE WEAR BEHAVIOUR OF ALUMINIUM
Metals and alloys have found their many role in many applications like structural and corrosive, environment. The alloys/composites having high strength to low weight ratio have gained attention of many researchers. In the above work, Aluminium metal matrix composite was prepared by die casting route, by varying the weight % of reinforcement. Made composite specimens are subjected to 3-body abrasive testing by varying applied load and time, the epoxy particles of 900 grit size were used as abrasive particles. It was observed that with increase of weight of wear resistance of composite was also increasing and on comparison it was found reinforced composite gives good wear resistance to the base alloy.
Investigation on cutting tool wear in turning Al 7075/SiCp metal matrix composite
IOP Conference Series: Materials Science and Engineering, 2018
Influence of machining process parameters on the tool flank wear (VBc) was investigated and optimized during turning silicon carbide particulate (SiCp) reinforced Al 7075 (Al 7075/SiCp) metal matrix composite (MMC) in heat treated condition. Metal removal was carried out by multilayer TiN coated tungsten carbide inserts in dry environment. Mechanism of tool failure was also studied. ANOVA revealed that the most significant machining parameter for VBc was cutting speed, followed by feed. Depth of cut was not significant. Quadratic response surface model was developed and its adequacy was verified.
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 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.
On the Role of Reinforcements on Tool Performance During Cutting of Metal Matrix Composites
Journal of Manufacturing Processes, 2006
Machining of metal matrix composites (MMCs) has been notoriously difficult due to the extremely abrasive nature of the reinforcements and presents a significant challenge to the industry. This paper presents an analytical tool flank wear rate model that has been developed for orthogonal cutting processes. In this approach, the wear volume loss is formulated based on the process parameters and reinforcement properties. Then, the flank wear rate is developed by considering the tool geometry in orthogonal metal cutting. The developed model was validated with orthogonal cutting tests conducted on 6061 aluminum MMC reinforced with AI O particulates of different average sizes (9.5 pm, 20 pro, 25 t~m~ and volume fractions (10% and 20%) under similar cutting conditions. The results showed good agreement between the predicted and measured flank wear data.
Abrasive Wear of Continuous Fibre Reinforced Al And Al-Alloy Metal Matrix Composites
2010
The abrasive wear testing of continuous ceramic fibre reinforced Al and Al-alloy matrix composites is proven difficult due to inherent complexity of the many wear processes, compounded by the possible interplay with microstructural variables in Metal matrix composites. This paper reports the results of abrasive wear tests on specimens of continuous Silicon Carbide (SiC) and high strength Carbon (H.S.C) fibres reinforced Al(1100) and Al(6061) matrix materials, with 5060% fibre volume fraction, and made by matrix fibre coating and hot-consolidation fabrication process. The test results for fibres parallel to the sliding direction of Al2O3 (alumina) abrasive papers with abrasive grit sizes 85 m μ to 250 m μ , at sliding speeds of 76, 110, 160 and 180 mm/s, and applied load ranging from 5 to 15 kg for a time (t), show that the test can be applied to continuous fibre reinforced metal matrix composites, and their addition has resulted in a large reduction of abrasion rate by a factor of m...