An Investigation on Machining Behaviour of Metal Matrix Composites by Using PCD Inserts

2005 ◽  
Author(s):  
N. Muthu Krishnan ◽  
D. Vikram ◽  
S. Kaushik ◽  
K. Prahalada Rao
Keyword(s):  
Tool Wear ◽  
Metal Matrix ◽  
Material Removal ◽  
Wear Behavior ◽  
Removal Rate ◽  
Cutting Tools ◽  
Depth Of Cut ◽  
Matrix Composites ◽  
Worn Surface ◽  
Poly Crystalline Diamond

The present work has been undertaken to study the tool wear behavior of poly crystalline diamond (PCD) inserts during the machining of Al-SiC – MMC; Al-Si alloy containing 15%wt of SiC was used for machining and PCD inserts of three different grades were used as cutting tools. The main aim of this paper is to explore the feasibility of machining conditions by setting the spindle speed, depth of cut and thereby determining the cutting force, surface roughness, power consumed, material removal rate and tool wear. The worn surface of the insert was examined by Scanning electron microscope (SEM). The influence of cut was examined for the PCD inserts.

Process Design and Optimization of end Milling Parameters of Al 7075 Metal Matrix Composite

2021 ◽  
pp. 929-937
Author(s):  
D. S. Sai Ravi Kiran ◽  
Alavilli Sai Apparao ◽  
Vempala GowriSankar ◽  
Shaik Faheem ◽  
Sheik Abdul Mateen ◽  
...  
Keyword(s):  
Tool Wear ◽  
Material Removal Rate ◽  
Metal Matrix ◽  
Material Removal ◽  
Hybrid Composites ◽  
End Milling ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Weight Percentage

This paper investigates the machinability characteristics of end milling operation to yield minimum tool wear with the maximum material removal rate using RSM. Twenty-seven experimental runs based on Box-Behnken Design of Response Surface Methodology (RSM) were performed by varying the parameters of spindle speed, feed and depth of cut in different weight percentage of reinforcements such as Silicon Carbide (SiC-5%, 10%,15%) and Alumina (Al2O3-5%) in alluminium 7075 metal matrix. Grey relational analysis was used to solve the multi-response optimization problem by changing the weightages for different responses as per the process requirements of quality or productivity. Optimal parameter settings obtained were verified through confirmatory experiments. Analysis of variance was performed to obtain the contribution of each parameter on the machinability characteristics. The result shows that spindle speed and weight percentage of SiC are the most significant factors which affect the machinability characteristics of hybrid composites. An appropriate selection of the input parameters such as spindle speed of 1000 rpm, feed of 0.02 mm/rev, depth of cut of 1 mm and 5% of SiC produce best tool wear outcome and a spindle speed of 1838 rpm, feed of 0.04 mm/rev, depth of cut of 1.81 mm and 6.81 % of SiC for material removal rate.

Optimization of Cutting Parameters in Milling Process Using Genetic Algorithm and ANOVA (March 2020)

2020 ◽  
Vol 38 (10A) ◽  
pp. 1489-1503
Author(s):  
Marwa Q. Ibraheem
Keyword(s):  
Genetic Algorithm ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Optimal Value ◽  
Optimization Of Cutting Parameters

In this present work use a genetic algorithm for the selection of cutting conditions in milling operation such as cutting speed, feed and depth of cut to investigate the optimal value and the effects of it on the material removal rate and tool wear. The material selected for this work was Ti-6Al-4V Alloy using H13A carbide as a cutting tool. Two objective functions have been adopted gives minimum tool wear and maximum material removal rate that is simultaneously optimized. Finally, it does conclude from the results that the optimal value of cutting speed is (1992.601m/min), depth of cut is (1.55mm) and feed is (148.203mm/rev) for the present work.

Modeling the abrasive wear behavior of in-situ synthesized magnesium RZ5/TiB2 metal matrix composites

2021 ◽  
pp. 095440892110655
Author(s):  
Arabinda Meher ◽  
Manas Mohan Mahapatra ◽  
Priyaranjan Samal ◽  
Pandu R. Vundavilli
Keyword(s):  
Abrasive Wear ◽  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Tribological Behavior ◽  
Wear Behavior ◽  
Wear Test ◽  
Regression Equation ◽  
Matrix Composites ◽  
Worn Surface ◽  
Anova Technique

In the present study, the statistical analysis on tribological behavior of RZ5/TiB2 magnesium-based metal matrix composites is carried out using Taguchi design and analysis of variance (ANOVA) technique. Taguchi analysis using signal-to-noise ratio indicates that the sliding distance and wt.% TiB2 are the most significant factors in evaluating weight loss and coefficient of friction, respectively. The regression equation is formulated utilizing the ANOVA technique to study the output responses based on the input abrasive wear test experimental results. The regression equation is validated through a comprehensive study taking a series of abrasive wear tests and indicates the percentage deviation of regression modeling is in the range of ± 10%. The individual and combined effect of wear parameters on tribological behavior are investigated through the main effect plots and response surface plots. The micrograph of the worn surface of RZ5/TiB2 composites is studied using field emission scanning electron microscope (FESEM), indicating the formation of an oxide layer on the worn surface.

Wear, optimization and surface analysis of Al-Al2O3-TiO2 hybrid metal matrix composites

2020 ◽  
Vol 235 (1) ◽  
pp. 93-102
Author(s):  
Naseem Ahamad ◽  
Aas Mohammad ◽  
Kishor Kumar Sadasivuni ◽  
Pallav Gupta
Keyword(s):  
Wear Rate ◽  
Metal Matrix Composites ◽  
Vickers Hardness ◽  
Hybrid Composite ◽  
Metal Matrix ◽  
Wear Behavior ◽  
Equal Proportion ◽  
Matrix Composites ◽  
Hybrid Metal Matrix Composites ◽  
Worn Surface

The aim of the present work is to investigate vickers hardness, wear behavior as well as to perform optimization of wear data for pure Al and Al-Al2O3-TiO2 hybrid metal matrix composites. The hybrid composite (Al-Al2O3-TiO2) was prepared by mechanical stir casting with equal proportion of reinforcement (2.5, 5.0, 7.5 and 10 wt.%). Vickers hardness, wear behavior and its optimization using ANOVA as well as TOPSIS along with the microstructure of the worn surface of prepared sample has been investigated. Vickers hardness increases with an increase in weight percentage of reinforcements. Wear test was carried out under dry sliding condition by pin-on-disc wear machine according to the ASTM G99-95a standard. Wear properties of the sample have been obtained at different percentages of reinforcement. Wear resistance of the hybrid composite increases with the variation of percentage of titanium oxide particles due to its lubricating properties. ANOVA shows that the reinforcements and load have different effect on samples wear rate. TOPSIS analysis shows rank of the sample according to its wear rate. Worn surface morphology was investigated and it showed deep grooves, more debris, delamination and rough surface in pure Al sample as compared to the high percentage of reinforced hybrid metal matrix composites.

Reinforcement and Cutting Tools Interaction during MMC Machining - A Review

2018 ◽  
Vol 22 ◽  
pp. 47-54 ◽  
Author(s):  
Mukesh Chaudhari ◽  
M. Senthil Kumar
Keyword(s):  
Tool Wear ◽  
Metal Matrix Composites ◽  
Process Parameters ◽  
Surface Finish ◽  
Metal Matrix ◽  
Cutting Tools ◽  
Tool Geometry ◽  
Matrix Composites ◽  
Good Surface ◽  
Aerospace Medical

Aluminum based metal matrix composites (AMMC) have found its applications in the automobile, aerospace, medical, and metal industries due to their superior mechanical properties. Fabricated Aluminum based metal matrix composites require machining to improve the surface finish and dimensional tolerance. Machining should be accomplished by good surface finish by consuming lowest energy and less tool wear. This paper reviews the machining of Aluminum based metal matrix composites to investigate the effect of process parameters such as tool geometry, tool wear, surface roughness, chip formation and also process parameters.

scholarly journals Multi-Response Optimization of process Parameter in Vertical Milling Machine of EN 31 Using Taguchi Method

2021 ◽  
Vol 23 (11) ◽  
pp. 228-235
Author(s):  
Sunil Kumar ◽  
◽  
P.N . Rao ◽  
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Tool Wear Rate ◽  
Vertical Milling Machine ◽  
En 31

The purpose of this experimental research is to compare the effectiveness of using Taguchi approaches for multi-response optimization of process parameters in Vertical Milling Machine of EN 31 Material intending to minimize surface roughness and tool wear rate while maximizing material removal rate to improve the productivity of the process with coated carbide insert. Taguchi L9 and Annova have been applied for experimental design and analysis. This experiment shows that feed and depth of cut are factors that are important for tool wear, Depth of cut is a notable factor for Material Removal Rate and feed is the most notable factor for surface roughness. Spindle speed has little effect on tool wear rate, surface roughness, and material removal rate. Mathematical models for three response parameters i.e. tool wear rate, surface roughness, and material removal rate were obtained by regression analysis

scholarly journals Pengaruh Variasi Tekanan Kompaksi Powder Metallurgy Elektroda Metal Matrix Composites Tembaga - Grafit Terhadap Material Removal Rate Dan Electrode Relative Wear Pada Proses EDM Mesin Chimer EZ

2020 ◽  
Vol 3 (1) ◽  
pp. 46-54
Author(s):  
Dwi Handoko
Keyword(s):  
Powder Metallurgy ◽  
Metal Matrix Composite ◽  
Metal Matrix Composites ◽  
Matrix Composite ◽  
Material Removal Rate ◽  
Metal Matrix ◽  
Material Removal ◽  
Removal Rate ◽  
Matrix Composites ◽  
Relative Wear

Pada penelitian ini dilakukan pembuatan metal matrix composite dari bahan serbuk tembaga murni yang akan dipadu dengan bahan penguat berupa serbuk grafit yang dilanjutkan dengan pengujian pada mesin EDM. Metode pencampuran kedua material ini dilakukan dengan proses Powder metalurgi melalui tahapan pencampuran (mixing), penekanan (compaction) dan dilanjutkan dengan proses pemanasan dengan suhu 800 oC(sintering). Pada penelitian ini ingin diketahui pengaruh tekanan akibat proses powder metalurgi terhadap laju keausan material (MRR) dan laju keausan elektroda (ERR) pada material baja ST.37 mesin EDM Chimer EZ Dengan parameter pemakan tetap, arus 2 Amper dan kedalaman 5 mm. Pengujian yang dilakukan yaitu kekerasan dan struktur mikro. Dari hasil penelitian ini menunjukkan dengan semakin meningkatnya tekanan kompaksi laju keausan material MRR dan kekerasan semakin meningkat, sementara laju keausan terendahi terjadi pada tekanan kompaksi 25.000 KN

scholarly journals Towards Optimization of Surface Roughness and Productivity Aspects during High-Speed Machining of Ti–6Al–4V

Materials ◽  
2019 ◽  
Vol 12 (22) ◽  
pp. 3749 ◽  
Author(s):  
Adel T. Abbas ◽  
Neeraj Sharma ◽  
Saqib Anwar ◽  
Faraz H. Hashmi ◽  
Muhammad Jamil ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Optimization Approach ◽  
High Speed Machining

Nowadays, titanium alloys are achieving a significant interest in the field of aerospace, biomedical, automobile industries especially due to their extremely high strength to weight ratio, corrosive resistance, and ability to withstand higher temperatures. However, titanium alloys are well known for their higher chemical reactive and low thermal conductive nature which, in turn, makes it more difficult to machine especially at high cutting speeds. Hence, optimization of high-speed machining responses of Ti–6Al–4V has been investigated in the present study using a hybrid approach of multi-objective optimization based on ratio analysis (MOORA) integrated with regression and particle swarm approach (PSO). This optimization approach is employed to offer a balance between achieving better surface quality with maintaining an acceptable material removal rate level. The position of global best suggested by the hybrid optimization approach was: Cutting speed 194 m/min, depth of cut of 0.1 mm, feed rate of 0.15 mm/rev, and cutting length of 120 mm. It should be stated that this solution strikes a balance between achieving lower surface roughness in terms of Ra and Rq, with reaching the highest possible material removal rate. Finally, an investigation of the tool wear mechanisms for three studied cases (i.e., surface roughness based, productivity-based, optimized case) is presented to discuss the effectiveness of each scenario from the tool wear perspective.

Laser-Assisted Machining of a Fiber Reinforced Metal Matrix Composite

2010 ◽  
Vol 132 (6) ◽  
Author(s):  
Chinmaya R. Dandekar ◽  
Yung C. Shin
Keyword(s):  
Tool Wear ◽  
Metal Matrix ◽  
Material Removal ◽  
Volume Fraction ◽  
Cutting Speed ◽  
Subsurface Damage ◽  
Matrix Composites ◽  
Specific Cutting Energy ◽  
Laser Assisted Machining ◽  
Cutting Energy

Metal matrix composites, due to their excellent properties of high specific strength, fracture resistance, and corrosion resistance, are highly sought after over their nonferrous alloys, but these materials also present difficulty in machining. Excessive tool wear and high tooling costs of diamond tools make the cost associated with machining of these composites very high. This paper is concerned with the machining of high volume fraction long-fiber metal matrix composites (MMCs), which has seldom been studied. The composite material considered for this study is an Al–2% Cu aluminum matrix composite reinforced with 62% by volume fraction alumina fibers (Al–2% Cu/Al2O3). Laser-assisted machining (LAM) is utilized to improve the tool life and the material removal rate while minimizing the subsurface damage. The effectiveness of the laser-assisted machining process is studied by measuring the cutting forces, specific cutting energy, surface roughness, subsurface damage, and tool wear under various material removal temperatures. A multiphase finite element model is developed in ABAQUS/STANDARD to assist in the selection of cutting parameters such as tool rake angle, cutting speed, and material removal temperature. The multiphase model is also successful in predicting the damage depth on machining. The optimum material removal temperature is established as 300°C at a cutting speed of 30 m/min. LAM provides a 65% reduction in the surface roughness, specific cutting energy, tool wear rate, and minimum subsurface damage over conventional machining using the same cutting conditions.

Sign in / Sign up

Export Citation Format

Share Document