Chaotic Tool Wear During Machining of Titanium Metal Matrix Composite (TiMMCs)

2014 ◽  
Author(s):  
Xuan-Truong Duong ◽  
Marek Balazinski ◽  
René Mayer
Keyword(s):  
Mathematical Model ◽  
Tool Wear ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Tool Life ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Titanium Metal

The initial tool wear during machining of titanium metal matrix composite (TiMMCs) is the result of several wear mechanisms: tool layer damage, friction - tribological wear, adhesion, diffusion and brace wear. This phenomenon occurs at the first instant and extends to only ten seconds at most. In this case the adhesive wear is the most important mechanism while the brace wear is considered as a resistance wear layer at the beginning of the steady wear period. In this paper, the effect of the initial tool wear and initial cutting conditions on tool wear progression and tool life is investigated. We proposed herein a new mathematical model based on the scatter wear and Lyapunov exponent to study quantitatively the “chaotic tool wear”. The Chaos theory, which has proved efficient in explaining how something changes in time, was used to demonstrate the dependence of the tool life on the initial cutting conditions and thus contribute to a better understanding of the influence of the initial cutting condition on the tool life. Based on the chaotic tool wear model, the scatter wear dimension and Lyapunov exponents were found to be positive in all case of the initial cutting conditions such as initial speed, feed rate and depth of cut. The initial cutting speed appears however to have the most significant impact on tool life. In particular, the mathematical model was successfully applied to the case of machining TiMMCs. It was clearly shown that changing the initial cutting speed by 20 m/min for the first two seconds of machining instead of keeping it constant at 60 m/min during the whole cutting process leads to an increase in the tool life (up to 24%).

Tool Wear and Surface Roughness when Machining AlSi/AlN Metal Matrix Composite Using Uncoated Carbide Cutting Tool

2013 ◽  
Vol 773-774 ◽  
pp. 409-413 ◽  
Author(s):  
M.S. Said ◽  
J.A. Ghani ◽  
Che Hassan Che Haron ◽  
Shahrizan Yusoff ◽  
Mohd Asri Selamat ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Milling Process ◽  
Cutting Condition ◽  
Carbide Cutting Tool

Aluminium silicon alloy (AlSic) matrix composite reinforced with aluminium nitride (AlN) particle is a new generation material for automotive and aerospace application. This material has low density, light weight, high strength, high hardness and stiffness. Metal Matrix Composit (MMC) material is one of the advanced materials which have good future prospects. This paper presents the study of tool wear and surface roughness investigation when milling AlSi/AlN Metal Matrix Composite using uncoated carbide cutting tool. The volume of AlN reinforced particle was 10%. The milling process was carried out under dry cutting condition. The uncoated carbide insert parameters used were cutting speed of (250-750 m/min), while feed rate and depth of cut were kept constant at 0.15 mm/tooth of 0.3mm respectively. The Sometech SV-35 video microscope system and Mitutoyo surface roughness tester were used for tool wear measurements and surface roughness respectively. The results revealed that the tool wear increases with cutting speed (450 m/min). While at high cutting speed, the surface finish improves. It was found that the cutting speed of 750m/min was optimum condition for obtaining smooth finish and longer tool life. Keywords: AlSi/AlN Metal Matrix Composite milling process, tool wear, and surface roughness, uncoated cemented carbide tool

scholarly journals Machining of Titanium Metal Matrix Composites: Progress Overview

Materials ◽  
2020 ◽  
Vol 13 (21) ◽  
pp. 5011
Author(s):  
Cécile Escaich ◽  
Zhongde Shi ◽  
Luc Baron ◽  
Marek Balazinski
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanisms ◽  
Metal Matrix ◽  
Dust Emission ◽  
Cutting Speed ◽  
Matrix Composites ◽  
Titanium Metal ◽  
Machining Processes ◽  
Tool Wear Mechanisms

The TiC particles in titanium metal matrix composites (TiMMCs) make them difficult to machine. As a specific MMC, it is legitimate to wonder if the cutting mechanisms of TiMMCs are the same as or similar to those of MMCs. For this purpose, the tool wear mechanisms for turning, milling, and grinding are reviewed in this paper and compared with those for other MMCs. In addition, the chip formation and morphology, the material removal mechanism and surface quality are discussed for the different machining processes and examined thoroughly. Comparisons of the machining mechanisms between the TiMMCs and MMCs indicate that the findings for other MMCs should not be taken for granted for TiMMCs for the machining processes reviewed. The increase in cutting speed leads to a decrease in roughness value during grinding and an increase of the tool life during turning. Unconventional machining such as laser-assisted turning is effective to increase tool life. Under certain conditions, a “wear shield” was observed during the early stages of tool wear during turning, thereby increasing tool life considerably. The studies carried out on milling showed that the cutting parameters affecting surface roughness and tool wear are dependent on the tool material. The high temperatures and high shears that occur during machining lead to microstructural changes in the workpiece during grinding, and in the chips during turning. The adiabatic shear band (ASB) of the chips is the seat of the sub-grains’ formation. Finally, the cutting speed and lubrication influenced dust emission during turning but more studies are needed to validate this finding. For the milling or grinding, there are major areas to be considered for thoroughly understanding the machining behavior of TiMMCs (tool wear mechanisms, chip formation, dust emission, etc.).

Influence of the cutting condition on the wear and the surface roughness in the steel AISI 4140 with mixed ceramic and diamond tool

2018 ◽  
Vol 16 (6) ◽  
pp. 828-836
Author(s):  
Razika Aouad ◽  
Idriss Amara
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Tool Wear ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Condition ◽  
Content Type ◽  
Aisi 4140 ◽  
Steel Aisi ◽  
Mixed Ceramic

PurposeThe purpose of this paper is to study the influence of the cutting conditions (cutting speed, feed rate and cutting depth) on the roughness (Ra) and on the flank wear (Vb) of the steel AISI 4140.Design/methodology/approachMixed ceramic (CC650) and polycrystalline cubic boron nitride (PCBN) have been used to carry out straight turning tests under dry conditions.FindingsThe results indicate that PCBN is more efficient than mixed ceramic (Al2O3+TiC) used in terms of wear resistance regardless of the aggressiveness of the AISI 4140 at 50 hardness rockwell (HRC). Consequently, it is the most powerful. Surface quality attained with PCBN tool considerably compares with that of grinding. Even when the tool wear VB reached 0.3 mm, the majority of the recorded Ra values did not exceed 1 m at the various speeds tested. The correlation of tool wear Vb and surface roughness Ra established allows obtaining experimental empirical data on the cutting tool wear from measured surface roughness for practical use in industry. The values of constants and the coefficient of determinationR2of this mathematical model will be calculated. Mathematical models expressing the relation between the elements of the cutting regime and technological parameters (tool life and roughness) are proposed.Originality/valueMany works have been already made in the similar manner, but this study of CC650 and PCBN wear is the first. Through this study, we propose a mathematical model expressing the relation between the elements of the cutting regime, tool life and roughness.

Tool Wear in Machining AlSi/AlN Metal Matrix Composite 10 Wt% Reinforcement Using Uncoated Cutting Tool

2013 ◽  
Vol 465-466 ◽  
pp. 973-977
Author(s):  
M.S. Said ◽  
M.S. Yusoff ◽  
C.H. Che Hassan ◽  
Mohd Asri Selamat ◽  
J.A. Shukur ◽  
...  
Keyword(s):  
Tool Wear ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Low Density ◽  
Industrial Sectors

Aluminum silicon (Al/Si) alloy, a metal matrix composite (MMC), is widely used in various industrial sectors, such as transportation, domestic equipment, aerospace, military, and construction. Al/Si alloy is a matrix composite reinforced with aluminum nitride (AlN) particle and transformed into a new-generation material for automotive and aerospace applications. AlN material is an advanced material characterized by light weight, high strength, and high hardness and stiffness, which makes it suitable for various future applications. However, its high ceramic particle reinforcement and the irregular nature of these particles along the matrix material make it a low density material. This low density is the main cause of problems during machining of this material. This paper studies tool wear in milling AlSi/AlN metal matrix composite by using an uncoated carbide cutting tool. The volume of AlN reinforced particle was 10%. The milling process was carried out under dry cutting conditions. The uncoated carbide insert parameters used were the following: cutting speed of 230 m/min to 370 m/min, feed rate of 0.4, 0.6, and 0.8 mm/tooth, and a corresponding depth of cut (DOC) of 0.3, 0.4, and 0.5 mm, respectively. Sometech SV-35 video microscope system was used for tool wear measurements. Results revealed that tool wear increases at 230 m/min cutting speed, 0.4 mm/tooth feed rate, and 0.3 mm depth of cut. The medium cutting speed, specifically the 300 m/min cutting speed, 0.4 mm/tooth feed rate, and 0.5 mm DOC, is the optimum condition for a longer tool life (82.94 min) and is ideal for cutting AlSi/AlN MMCs.

Effect of machining parameters on the surface finish of a metal matrix composite under dry cutting conditions

2015 ◽  
Vol 231 (6) ◽  
pp. 913-923 ◽  
Author(s):  
Brian Boswell ◽  
Mohammad Nazrul Islam ◽  
Ian J Davies ◽  
Alokesh Pramanik
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Tool Life ◽  
Surface Finish ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dry Cutting

The machining of aerospace materials, such as metal matrix composites, introduces an additional challenge compared with traditional machining operations because of the presence of a reinforcement phase (e.g. ceramic particles or whiskers). This reinforcement phase decreases the thermal conductivity of the workpiece, thus, increasing the tool interface temperature and, consequently, reducing the tool life. Determining the optimum machining parameters is vital to maximising tool life and producing parts with the desired quality. By measuring the surface finish, the authors investigated the influence that the three major cutting parameters (cutting speed (50–150 m/min), feed rate (0.10–0.30 mm/rev) and depth of cut (1.0–2.0 mm)) have on tool life. End milling of a boron carbide particle-reinforced aluminium alloy was conducted under dry cutting conditions. The main result showed that contrary to the expectations for traditional machined alloys, the surface finish of the metal matrix composite examined in this work generally improved with increasing feed rate. The resulting surface roughness (arithmetic average) varied between 1.15 and 5.64 μm, with the minimum surface roughness achieved with the machining conditions of a cutting speed of 100 m/min, feed rate of 0.30 mm/rev and depth of cut of 1.0 mm. Another important result was the presence of surface microcracks in all specimens examined by electron microscopy irrespective of the machining condition or surface roughness.

Measurement and prediction of residual stresses in a titanium metal matrix composite ring

2001 ◽  
Vol 9 (2) ◽  
pp. 373-379 ◽  
Author(s):  
J. W. L. Pang ◽  
G. Rauchs ◽  
P. J. Withers ◽  
N. W. Bonner ◽  
E. S. Twigg
Keyword(s):  
Residual Stresses ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Titanium Metal ◽  
Composite Ring

scholarly journals Tool wear and surface quality of metal matrix composites due to machining: A review

2016 ◽  
Vol 231 (5) ◽  
pp. 739-752 ◽  
Author(s):  
Ferial Hakami ◽  
Alokesh Pramanik ◽  
Animesh K Basak
Keyword(s):  
Tool Wear ◽  
Metal Matrix Composite ◽  
Metal Matrix Composites ◽  
Surface Quality ◽  
Tool Life ◽  
Metal Matrix ◽  
Cutting Tool ◽  
Matrix Composites ◽  
Machined Surface

Higher tool wear and inferior surface quality of the specimens during machining restrict metal matrix composites’ application in many areas in spite of their excellent properties. The researches in this field are not well organized, and knowledge is not properly linked to give a complete overview. Thus, it is hard to implement it in practical fields. To address this issue, this article reviews tool wear and surface generation and latest developments in machining of metal matrix composites. This will provide an insight and scientific overview in this field which will facilitate the implementation of the obtained knowledge in the practical fields. It was noted that the hard reinforcements initially start abrasive wear on the cutting tool. The abrasion exposes new cutting tool surface, which initiates adhesion of matrix material to the cutting tool and thus causes adhesion wear. Built-up edges also generate at lower cutting speeds. Although different types of coating improve tool life, only diamond cutting tools show considerably longer tool life. The application of the coolants improves tool life reasonably at higher cutting speed. Pits, voids, microcracks and fractured reinforcements are common in the machined metal matrix composite surface. These are due to ploughing, indentation and dislodgement of particles from the matrix due to tool–particle interactions. Furthermore, compressive residual stress is caused by the particles’ indentation in the machined surface. At high feeds, the feed rate controls the surface roughness of the metal matrix composite; although at low feeds, it was controlled by the particle fracture or pull out. The coarser reinforced particles and lower volume fraction enhance microhardness variations beneath the machined surface.

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