FEM Simulation and Experimental Validation of Cold Forging Behavior of LM6 Base Metal Matrix Composites (original) (raw)
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The deformation characteristics during open-die forging of silicon carbide particulate reinforced aluminium metal matrix composites (SiC p AMC) at cold conditions are investigated. The material was fabricated by liquid stir casting method in which preheated SiC particles were mixed with molten LM6 aluminium casting alloy and casted in the silicon mould. Finally, preforms obtained were machined in required dimensions. Two separate cases of deformation, that is, open-die forging of solid disc and solid rectangular preforms, were considered. Both upper bound theoretical analysis and experimental investigations were performed followed by finite element simulation using DEFORM, considering composite interfacial friction law, barreling of preform vertical sides, and inertia effects, that is, effect of die velocity on various deformation characteristics like effective stress, strain, strain rate, forging load, energy dissipations, and height reduction. Results have been presented graphically and critically investigated to evaluate the concurrence among theoretical, experimental, and finite element based computational findings.
Materials Characterization, 2019
The material flow behavior of aluminium metal matrix composites at a high-temperature is required to manufacture the forged components for the lightweight application. In this study, four varieties of aluminium based composites such as Al/3 vol%SiC, Al/7 vol%SiC, Al/3 vol%Al 2 O 3 and Al/7 vol%Al 2 O 3 composites were synthesized using powder metallurgy route. Single step deformation was performed at 500°C to get a true unity strain at strain rates of 10/s −1 and 20s −1. In two-step, the first deformation was at 500°C followed by additional deformation at 430°C at strain rates of 10s −1 and 20s −1. The compression test results show the Al/7 vol% SiC composite exhibit comparatively higher value of peak true stress (46.36 MPa at a strain rate of 20s −1) at a temperature of 500°C in single step deformation. The interface coefficient of friction between anvils and specimen decreased with increase in strain rate. Electron backscatter diffraction (EBSD) maps revealed that, Al/ 7 vol% SiC p and Al/7 vol% Al 2 O 3p shows partially dynamically recrystallized grains at the interface of aluminium and the particulate reinforcements (SiC and Al 2 O 3) under a strain rate of 10s −1. Subgrain boundaries with dynamic recovery grains were observed in aluminium when it was deformed at strain rates of 10 s −1 and 20 s −1 to a true strain of 0.6. In the view of flow stress and evolution of microstructures, this investigation provides insight into the implementation of the forging process for aluminium metal matrix composite.
Effect of Forging Condition on Mechanical Properties of Al/SiC Metal Matrix Composites
International Journal of Engineering Research and, 2015
The objective of the research work to investigate effect of forging condition on mechanical properties of Al/SiC composites prepared in open die at the temperature of 450 °C with three different stages then specimens are aged at T6 conditions. Forged specimens subjected tensile, compression and hardness tests to evaluate effect of forging levels on Al/SiC composites. The effect of plastic deformation and high temperature during forging led to a recrystallization of the Al/SiC matrix with a grain refinement. At first and second stage higher grain refine could be seen but at third stage no further grain refinement could be absorbed. The modification of grain which was influenced an enhancement in the mechanical strength. The scanning electron microscope shows the brittle and ductile mixture failure was absorbed in all type of the specimens. Forging improve the mechanical properties with nominal loss of ductility.
IJERT-Effect of Forging condition on Mechanical Properties of Al/SiC Metal Matrix Composites
International Journal of Engineering Research and Technology (IJERT), 2015
https://www.ijert.org/effect-of-forging-condition-on-mechanical-properties-of-alsic-metal-matrix-composites https://www.ijert.org/research/effect-of-forging-condition-on-mechanical-properties-of-alsic-metal-matrix-composites-IJERTV4IS050635.pdf The objective of the research work to investigate effect of forging condition on mechanical properties of Al/SiC composites prepared in open die at the temperature of 450 °C with three different stages then specimens are aged at T6 conditions. Forged specimens subjected tensile, compression and hardness tests to evaluate effect of forging levels on Al/SiC composites. The effect of plastic deformation and high temperature during forging led to a recrystallization of the Al/SiC matrix with a grain refinement. At first and second stage higher grain refine could be seen but at third stage no further grain refinement could be absorbed. The modification of grain which was influenced an enhancement in the mechanical strength. The scanning electron microscope shows the brittle and ductile mixture failure was absorbed in all type of the specimens. Forging improve the mechanical properties with nominal loss of ductility.
International Journal of Materials Forming and Machining Processes, 2014
The deformation behaviour of solid aluminium alloy (LM6) and silicon carbide metal matrix composite cylinders under axi-symmetric compression over constant aspect ratios using different lubricants were examined. Dry condition and three different lubricants namely MoS2, graphite and white grease were prepared and cold upset forged. In the light of the previous studies, the calculations were made with the assumption that the curvatures of deformed specimens were in the form of a circular arc. The calculated radius of curvature of the bulge was found under different lubricating conditions. The flow curve of composite was determined by compression tests and data were used in simulation analysis. The FEA simulation was carried out using DEFORM software. Results gained by Finite Element Analysis and by experiment show high degree of similarity, so this way of modeling could be used for even more complex technology of plasticity.
A study on forging of aluminum-based metal matrix composites
International Journal of Material Forming, 2010
Due to its lightweight and high specific strength, aluminum-based metal matrix composites have drawn much attention from the forging industry for manufacturing structural components. In the present study, the forging formability of the aluminum-based metal matrix composites A6061/Al 2 O 3 was investigated with both the experimental approaches and the finite element analysis. The compression tests were conducted to obtain the stress-strain curves for the A6061/Al 2 O 3 composites at elevated temperatures ranging from the room temperature to 500°C under various strain rates of 0.05s-1 , 0.5s-1 and 5s-1 , respectively. The forging of a structural part with characteristic geometry features, including a circular cup at the top and a boss at the bottom, was also performed in the present study to investigate the forging formability of the A6061/Al 2 O 3 metal-matrix composites. The consistency between the experimental data and the finite element simulation results confirms the validity of the finite element analysis on the forging formability of the A6061/Al 2 O 3 metal-matrix composite and the die design proposed in the present study.
International Journal of Engineering Research and Technology (IJERT), 2013
https://www.ijert.org/a-study-of-microstructure-and-mechanical-properties-of-aluminium-silicon-carbide-metal-matrix-composites-mmcs https://www.ijert.org/research/a-study-of-microstructure-and-mechanical-properties-of-aluminium-silicon-carbide-metal-matrix-composites-mmcs-IJERTV2IS90295.pdf In the present study, silicon carbide particulate reinforced LM6 alloy matrix composites were produced by gravity die casting process by varying the particulate addition by weight fraction on percentage basis. Mechanical properties such as tensile, impact and wear test studies were conducted to determine the tensile strength, ductility, toughness and wear characteristics of cast MMC's. Micro structural properties of the as cast composites have also studied by using optical microscope. The experimental result reveals that the tensile property increases with increase in Sic, the toughness of composite decreases as silicon carbide percentage increases and the composite showed accountable increase in wear rate of cast MMC.
EXPERIMENTAL ANALYSIS OF MECHANICAL PROPERTIES OF ALUMINIUM ALLOY WITH SILICON CARBIDE
The objective of this research is to produce metal matrix composite (MMC) by stir casting technique. The metal matrix composite are prepared by using aluminium (Al 6063) as a matrix and Sic particulates as reinforced with different percentage of weight fraction ranging from 3.5, 6.5, 9.5, 12.5. The reinforced particles size of SIC are 220 mesh, 400 mesh respectively. The steel prices are growing high day by day those have an effect on manufacturing expense in automobile and domestic industries , that why it is necessary to substitute steel with material having light weight and high strong suit to weight proportion. The aluminium and its compounds have terrific characteristics like light weight, wear and resistance to the corrosion that make acceptable in copious industrial usage. This study analysis examines the micro-structural and mechanical properties of al 6063 with SIC reinforced metal matrix composites (MMC's).
Advances in Materials Science and Engineering
In this investigation, aluminium-silicon-based alloy (LM6) with the addition of (0, 2.5, 5, and 10%) copper-coated short steel fiber and 5% boron carbide (B4C) element-strengthened composites was fabricated by the stir casting method. Mechanical properties and tribological behaviors of LM6-based hybrid composites were investigated, and microstructures of different castings were examined by an image analyzer. The test was conducted at different loads (10, 20, 30, and 40 N) and different sliding spaces (500, 1000, 1500, and 2000 m), respectively. The results revealed that the sample loaded with 10% of reinforcement recorded the highest tensile strength of 231 MPa. On the other hand, the hardness value increased from 71 to 144 BHN, when 15% of reinforcement was added to the sample. It was also noted that 10% copper-coated steel fiber improved wear resistance up to 50% when compared to LM6. A field emission scanning electron microscope was employed to observe the morphology of the worn ...