On tool–workpiece interactions during machining metal matrix composites: investigation of the effect of cutting speed

2015 ◽  
Vol 84 (9-12) ◽  
pp. 2423-2435 ◽  
Author(s):  
A. Ghandehariun ◽  
H. A. Kishawy ◽  
U. Umer ◽  
H. M. Hussein
Keyword(s):  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Matrix Composites

Comparison of machining characteristics of metal matrix composites using CO2 laser curve cutting process

2017 ◽  
Vol 232 (3) ◽  
pp. 349-368 ◽  
Author(s):  
Vikas Sharma ◽  
Vinod Kumar
Keyword(s):  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Morphological Changes ◽  
Cutting Speed ◽  
Matrix Composites ◽  
Composites Materials ◽  
Input Variables ◽  
Output Characteristics ◽  
Metal Matrix Composite Material ◽  
Machining Characteristics

In the present work, the effects of input variables of laser beam machining on the machining characteristics of the metal matrix composites reinforced with SiC, Al2O3, and ZrO2 particles were investigated. The comparison of the machining characteristics has been done to analyze the behavior of various reinforced particles with the variation of laser machining variables. Various output characteristics such as dross height, kerf deviation, and striations angle have been investigated and compared with each metal matrix composite material. Parameters such as cutting speed, reinforced particles, and cut profile were found to be the most significant factors influencing the various output characteristics. The morphological changes in the structure have been examined using scanning electron microscopy and X-ray diffraction technique for the agglomeration of the reinforced particles. The crack and recast layer formation has been examined in the specimens of higher quantity of the reinforced particles. It was analyzed that the metal matrix composites material reinforced with SiC particles has shown different behaviors as compared to other metal matrix composites materials.

On the Optimisation Into Wire Electro-Discharge Machining of Al/Al2O3P Composites

2007 ◽  
Author(s):  
N. G. Patil ◽  
P. K. Brahmankar ◽  
L. G. Navale
Keyword(s):  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Kerf Width ◽  
Feed Speed ◽  
Machining Parameters ◽  
Matrix Composites ◽  
Electro Discharge Machining ◽  
Pulse On Time ◽  
Machining Parameter

Non-traditional process like wire electro-discharge machining (WEDM) is found to show a promise for machining metal matrix composites (MMCs). However, the machining information for the difficult-to-machine particle-reinforced material is inadequate. This paper is focused on experimental investigation to examine the effect of electrical as well as nonelectrical machining parameters on performance in wire electro-discharge machining of metal matrix composites (Al/Al2O3p). Taguchi orthogonal array was used to study the effect of combination of reinforcement, current, pulse on-time, off-time, servo reference voltage, maximum feed speed, wire speed, flushing pressure and wire tension on kerf width and cutting speed. Reinforcement percentage, current, on-time was found to have significant effect on cutting rate and kerf width. The optimum machining parameter combinations were obtained for cutting speed and kerf width separately.

Surface integrity in machining of AZ91/SiC composites

2021 ◽  
pp. 095440622110179
Author(s):  
A Asgari ◽  
M Sedighi
Keyword(s):  
Metal Matrix Composites ◽  
Surface Integrity ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Depth Of Cut ◽  
Matrix Composites ◽  
Machined Surface ◽  
Sic Particles ◽  
Finished Surface

Use of metal matrix composites (MMC) is growing due to their high strength-to-weight ratio, resistance to wear, creep, etc. Machining of metal-matrix composites (MMC) faces many challenges, especially with regard to obtaining a finished surface with high quality. In this research, AZ91/SiC samples with different volume fractions are machined at different cutting conditions with respect to feed rate, cutting speed, and depth of cut. Surface integrity of the machined samples is analyzed by different methods such as tactile profilometer and 3D surface topography to investigate the SiC effects on the finished surface. Additionally, sample surfaces are evaluated by scanning electron microscope (SEM) and with energy-dispersive X-ray (EDS) to assess the surface defects formed around reinforcement materials. Results indicate SiC particles decline the surface quality and uniformity due to the formation of some defects such as micro cracks, holes, and undesired deformations when the cutting process. Also, subsurface SiC particles close to the machined surface are cracked after machining.

Effect of SiCp Reinforcement on Machinability of A356 Alloy Metal Matrix Composites

2016 ◽  
Vol 852 ◽  
pp. 142-148
Author(s):  
K. Jayakumar
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composites ◽  
Metal Matrix ◽  
End Milling ◽  
Cutting Speed ◽  
A356 Alloy ◽  
Experimental Result ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Matrix Composites

Machining of Aluminum Metal Matrix Composites (AMMCs) is a challenge for manufacturing industries due to their heterogeneous constituents which vary from soft matrix to hard reinforcements and their interfaces. To overcome the difficulties in machining of MMCs, researchers are continuously working to find the optimum process or machining parameters. In this work, End milling studies were carried out in A356 alloy powder-SiC particles (1 μm) in 0, 5, 10, 15 volume % reinforced AMMCs synthesised by vacuum hot pressing (VHP) route.The influence of machining parameters such as cutting speed, feed and depth of cut on the prepared composites in terms of surface roughness (Ra) and material removal rate (MRR) are measured from experimental study. Experiments were conducted as per Taguchi L16 orthogonal array with 4 factors and 4 levels.From the experimental result, it was identified that surface roughness varied from 0.214 μm to 4.115 μm and MRR varied from minimum of 1.11 cm3/min to maximum of 9.65 cm3/min. It is also observed that, MRR increased with increase in machining parameters and reinforcement quantity. Similarly, surface roughness decreased for increase of cutting speed, SiC particle (SiCp) reinforcement and increased for increase in feed and depth of cut. The optimum condition were observed in higher speed, lower feed and higher depth of cut on MMC with higher SiC content (15%) for getting higher machinability.

Some Investigations Into Multi-Objective Optimization of Wire Electro-Discharge Machining of Al/SiCp Composites

2007 ◽  
Author(s):  
N. G. Patil ◽  
P. K. Brahmankar ◽  
L. G. Navale
Keyword(s):  
Metal Matrix Composites ◽  
Grey Relational Analysis ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Kerf Width ◽  
Matrix Composites ◽  
Multi Objective Optimization ◽  
Relational Analysis ◽  
Electro Discharge Machining ◽  
Grey Relational

Non-traditional process like wire electro-discharge machining (WEDM) is found to show a promise for machining metal matrix composites (MMCs). However, the machining information for the difficult-to-machine particle-reinforced material is inadequate. This paper is focused on experimental investigation to examine the effect of electrical as well as non-electrical machining parameters on performance in wire electro-discharge machining of metal matrix composites (Al/SiCp). Taguchi orthogonal arrays were employed to study the effects of combinations of voltage, current, pulse on-time, off-time, and wire speed and wire tension on kerf width and cutting speed. Voltage, current, and on-time were found to have significant effect on cutting speed and kerf width. The optimum machining parameter combinations were obtained for cutting speed and kerf width separately. Further, multi-objective optimization was done using Taguchi-Grey relational analysis. The process has been improved with the aid of Grey relational analysis and Taguchi orthogonal array. The results have been verified with confirmation experiments.

Roughness Analysis of the Holes Drilled on Al / SiC Metal Matrix Composites Using Atomic Force Microscope

2015 ◽  
Vol 766-767 ◽  
pp. 837-843
Author(s):  
S. Senthilbabu ◽  
B.K. Vinayagam ◽  
J. Arunraj
Keyword(s):  
Atomic Force Microscope ◽  
Metal Matrix Composites ◽  
Surface Finish ◽  
Metal Matrix ◽  
Vertical Section ◽  
Cutting Speed ◽  
Drilling Process ◽  
Matrix Composites ◽  
Average Roughness ◽  
Atomic Force

Metal matrix composites (MMCs) possess significantly improved properties including high strength to wear ratio, high modulus, superior wear resistance and corrosion resistance compared to unreinforced alloys. In spite of the advantages, the Aluminium based metal matrix composites have not yet found a wide employment in the commercial applications, because the the matrix cause serious problems in machining / drilling, such as high drilling forces, tool wear, and poor surface finish due to the hard particles. The drilling of Al/SiC metal matrix composite has received a serious attention for many years. Different specimens were prepared from Aluminium / Silicon carbide (Sic) metal matrix composites by stir casting method by varying the weight percentage of Sic and the investigation has been carried out on the specimen by drilling holes on them. Surface finish is an important factor to be taken into account in the drilling process. So, it is more necessary to predict the average surface roughness of the materials. Then the roughness of the drilled holes made on the specimen was studied using Atomic force microscope. The investigation was carried out with their characteristics being studied by comparing various parameters such as cutting speed, feed rate and so on. The average roughness was studied on 30µm X 30µm and 15 µm X 15µm horizontal section and vertical section. Their histograms were also studied.

Experimental Studies on Machinability of 14 wt.% of SiC Particle Reinforced Aluminium Alloy Composites

2012 ◽  
Vol 723 ◽  
pp. 94-98 ◽  
Author(s):  
Sheng Qin ◽  
Xiao Jiang Cai ◽  
Yu Sheng Zhang ◽  
Qing Long An ◽  
Ming Chen
Keyword(s):  
Metal Matrix Composites ◽  
Metal Matrix ◽  
End Milling ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Matrix Composites ◽  
Coated Carbide ◽  
Coated Carbide Tools ◽  
Aluminium Metal

Since metal matrix composites (MMCs) have increasing applications in industries, this paper presents an experimental investigation on machinability of SiCp reinforced aluminium metal matrix composites. 14 wt.% of SiCp reinforcement addition composite was studied in end milling using CVD coated carbide tools under different cutting parameters. By experimental results, the relationships of cutting force and surface roughness with cutting speed and feed were discussed. Some defects concerning surface topography such as ploughed furrow, pits, matrix tearing, etc. were examined by SEM.

The Influence of SiC Particles on Tool Wear in Machining of Al/SiC Metal Matrix Composites Produced by Powder Extrusion

2011 ◽  
Vol 325 ◽  
pp. 393-399 ◽  
Author(s):  
R. Yousefi ◽  
M.A. Kouchakzadeh ◽  
J. Rahiminasab ◽  
M.A. Kadivar
Keyword(s):  
Tool Wear ◽  
Metal Matrix Composites ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Test Method ◽  
Engineering Properties ◽  
Depth Of Cut ◽  
Matrix Composites ◽  
Sic Particles

Metal matrix composites (MMCs) have received considerable attention due to their excellent engineering properties. However, poor machinability has been the main deterrent to their substitution for metal parts. The hardness and abrasive nature of reinforcement phase causes rapid tool wear during machining which results in high machining costs. In this study, the effect of SiC particles (5, 15 & 20 percent) on tool wear in turning process is experimentally investigated. Continuous dry turning of Al/SiC particulate metal matrix composite produced by powder metallurgy and utilizing titanium carbide inserts has been achieved as the test method. The influence of machining parameters, e.g. cutting speed, feed rate and depth of cut on tool wear and cutting forces were investigated during the experiments. The results show that tool wear increases with increasing cutting speed, depth of cut and feed rate. The cutting speed and depth of cut are more dominant factors compared to feed rate on the tool wear. In addition, it is concluded that the flank wear increases with the increase of SiC percentage in the MMC.

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