Cutting force, tool wear and surface finish in drilling metal matrix composites

Author(s):  
J P Davim ◽  
A Monteiro Baptista
2018 ◽  
Vol 22 ◽  
pp. 47-54 ◽  
Author(s):  
Mukesh Chaudhari ◽  
M. Senthil Kumar

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.


Author(s):  
Ben Deng ◽  
Haowei Wang ◽  
Fangyu Peng ◽  
Rong Yan ◽  
Lin Zhou

During the machining processes of ceramic particle reinforced metal matrix composites, the severe tool wear constrains the quality and cost of the parts. This paper presents the experimental and theoretical investigations of the tool wear behavior and surface quality when micro milling the 45vol% SiCp/Al composites under dry and minimum quantity lubrication (MQL) conditions. The results of scanning electron microscope (SEM) and energy dispersive spectrometer (EDS) show that the wear mechanism of diamond coated micro mills are adhesive, abrasion, oxidization, chipping and tipping, even though it has been reported that abrasion is the most important tool wear mechanism when machining particle reinforced metal matrix composites. Compared with dry lubrication condition, the environmentally friendly MQL technique can enhance the tool life and surface roughness, and reduce the cutting force significantly under given cutting parameters. Then, finite element (FE) simulations are employed to investigate chip formation process in micro orthogonal cutting to reveal the effects of reinforced particle on tool wear and surface quality. The FE simulations shows the local high stress, hard reinforced particles in metal matrix, debonded and cracked particles are the key factors leading to the severe tool wear and the unsmoothed surface morphology.


Author(s):  
Zhichao Niu ◽  
Kai Cheng

The effects of cutting dynamics and the particles' size and density cannot be ignored in micro milling of metal matrix composites. This article presents the improved dynamic cutting force modelling for micro milling of metal matrix composites based on the previous analytical model. This comprehensive improved cutting force model, taking the influence of the tool run-out, actual chip thickness and resultant tool tip trajectory into account, is evaluated and validated through well-designed machining trials. A series of side milling experiments using straight flutes polycrystalline diamond end mills are carried out on the metal matrix composite workpiece under various cutting conditions. Subsequently, the measured cutting forces are compensated by a Kalman filter to achieve the accurate cutting forces. These are further compared with the predicted cutting forces to validate the proposed dynamic cutting force model. The experimental results indicate that the predicted and measured cutting forces in micro milling of metal matrix composites are in good agreement.


2013 ◽  
Vol 44 (8) ◽  
pp. 3757-3764 ◽  
Author(s):  
Tracie J. Prater ◽  
Alvin M. Strauss ◽  
George E. Cook ◽  
Brian T. Gibson ◽  
Chase D. Cox

Author(s):  
Ferial Hakami ◽  
Alokesh Pramanik ◽  
Animesh K Basak

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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