scholarly journals Experimental Investigation of Surface Roughness in Milling of DuralcanTM Composite

Materials ◽  
2021 ◽  
Vol 14 (20) ◽  
pp. 6010
Author(s):  
Martyna Wiciak-Pikuła ◽  
Paweł Twardowski ◽  
Aneta Bartkowska ◽  
Agata Felusiak-Czyryca
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Cutting Speed ◽  
Aluminum Matrix ◽  
Regression Tree ◽  
Machine Learning Algorithms ◽  
Classification And Regression Tree ◽  
Aluminum Matrix Composites ◽  
Matrix Composites ◽  
Roughness Prediction

In today’s developing aircraft and automotive industry, extremely durable and wear-resistant materials, especially in high temperatures, are applied. Due to this practical approach, conventional materials have been superseded by composite materials. In recent years, the application of metal matrix composites has become evident in industry 4.0. A study has been performed to analyze the surface roughness of aluminum matrix composites named Duralcan® during end milling. Two roughness surface parameters have been selected: arithmetical mean roughness value Ra and mean roughness depth Rz regarding the variable cutting speed. Due to the classification of aluminum matrix composites as hard-to-cut materials concerning excessive tool wear, this paper describes the possibility of surface roughness prediction using machine learning algorithms. In order to find the best algorithm, Classification and Regression Tree (CART) and pattern recognition models based on artificial neural networks (ANN) have been compared. By following the obtained models, the experiment shows the effectiveness of roughness prediction based on verification models. Based on experimental research, the authors obtained the coefficient R2 for the CART model 0.91 and the mean square error for the model ANN 0.11.

Research on Grinding of Silicon Particles Reinforced Aluminum Matrix Composites with High Volume Fraction

2014 ◽  
Vol 1017 ◽  
pp. 98-103
Author(s):  
Fei Hu Zhang ◽  
Kai Wang ◽  
Peng Qiang Fu ◽  
Meng Nan Wu
Keyword(s):  
Surface Roughness ◽  
Silicon Carbide ◽  
Volume Fraction ◽  
Aluminum Matrix ◽  
High Volume ◽  
Grinding Force ◽  
Aluminum Matrix Composites ◽  
Work Piece ◽  
Matrix Composites ◽  
Silicon Particles

With silicon particles reinforced aluminum matrix composites with high volume fraction becoming a new hotspot on research and application in the aerospace materials and electronic packaging materials, the machinability of this material needs to be explored. This paper reports research results obtained from the surface grinding experiment of silicon particles reinforced aluminum matrix composites using black silicon carbide wheel, green silicon carbide wheel, white fused alumina wheel and chromium alumina wheel. The issues discussed are grinding force, surface roughness, the comparison of different grinding wheels, the micro-morphology of the work piece. The results showed that the grinding force was related with the grinding depth and the grinding wheel material, the grinding force was increasing as the grinding depth growing. The surface roughness was between 0.29μm and 0.48μm using the silicon carbide wheel. The surface of the work piece had concaves caused by silicon particles shedding and grooves caused by the grains observed by the SEM and CLSM.

scholarly journals Drilling of Ceramic Reinforced Aluminum Matrix Composite under Dry Condition

2020 ◽  
Vol 9 (4) ◽  
pp. 3029-3033
Keyword(s):  
Surface Roughness ◽  
Matrix Composite ◽  
Cutting Speed ◽  
Aluminum Matrix ◽  
Cutting Parameters ◽  
Aluminium Matrix ◽  
Matrix Composites ◽  
Aluminium Matrix Composite ◽  
Aluminium Matrix Composites ◽  
Silicon Carbide Particulate

In this study an experimental investigation of effects of cutting parameters on surface roughness during drilling of silicon carbide particulate reinforced aluminium matrix composite material under dry condition was carried out. Cutting speed , feed rate and % SiC in aluminium matrix composites were chosen as cutting parameters. The experimental design adopted for this investigation was the central composite design of response surface methodology. Thirty one readings were taken on VMC machine for dry condition and the surface roughness measured using Mitutoyo surface tester. Surface roughness values for dry condition were lower with 30% SiC reinforced aluminium matrix composites when compared to 10 % and 20 % SiC reinforced aluminium matrix composites . As cutting speed increased Ra & Rz value also increased .% SiC was found most significant factor while drilling aluminium matrix composites.

Cutting Simulations and Experiments of Milled SiC Particle-Reinforced Aluminum Matrix Composites

2013 ◽  
Vol 856 ◽  
pp. 142-146
Author(s):  
Qiong Wu ◽  
Da Peng Li ◽  
Xiao Ju Shui
Keyword(s):  
Surface Roughness ◽  
Aluminum Matrix ◽  
Cutting Process ◽  
Aluminum Matrix Composites ◽  
Machining Accuracy ◽  
Matrix Composites ◽  
Al Matrix Composites ◽  
Tools Wear ◽  
Al Matrix ◽  
Sic Particle

When SiC particles are added into aluminum, property of aluminum is greatly improved during a reinforcing phase to produce particle reinforced aluminum composites. However, cutting tools wear out quickly and it is difficult to meet machining accuracy and surface quality requirements due to the rough surface produced by the reinforcement process. This paper presents a simulation model of SiC particle-reinforced aluminum matrix composites is established considering particles, cohesive elements, and material matrix. Stress distribution and surface roughness are analyzed for SiC/Al matrix composites based on the cutting process. Experiments are performed to test the degree of surface roughness using different cutting parameters. The relationship of cutting depth, cutting velocity, and feed rate per tooth to surface roughness degree is obtained for SiC/Al matrix composites. The optimization of cutting process is performed based on simulation. The results lay a foundation on the optimization of machining processes for metal matrix composites.

Surface Roughness Prediction in the End Milling Parameters of Aluminum Nitride Ceramic by Response Surface Methodology

2010 ◽  
Vol 154-155 ◽  
pp. 626-633
Author(s):  
Moola Mohan Reddy ◽  
Alexander Gorin ◽  
Khaled A. Abou-El-Hossein
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
End Milling ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Roughness Model ◽  
Roughness Prediction ◽  
Grinding Tool

The present experimental study aimed to examine the selected machining parameters on Surface roughness in the machining of alumina nitride ceramic. The influence of cutting speed and feed rate were determined in end milling by using Cubic boron nitride grinding tool. The predictive surface roughness model has been developed by response surface methodology. The response surface contours with respect to input parameters are presented with the help of Design expert software. The adequacy of the model was tested by ANOVA.

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.

Experimental Study on the Surface Roughness with Mill-Grinding SiC Particle Reinforced Aluminum Matrix Composites

2011 ◽  
Vol 188 ◽  
pp. 203-207 ◽  
Author(s):  
Jian Guang Li ◽  
Jin Guang Du ◽  
Hang Zhao
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Aluminum Matrix ◽  
Speed Ratio ◽  
Aluminum Matrix Composites ◽  
Matrix Composites ◽  
Sic Particle

In view of the present machining status of SiC particle reinforced aluminum matrix composites, the electroplated diamond wheel (80# diamond grit) was used for mill-grinding the SiC particle reinforced aluminum matrix composites and the effect of speed ratio (q) and material removal rate (MRR) on surface roughness was studied based on experiments. The experimental results show that surface roughness almost increases with the increase of speed ratio. At the same material removal rate, surface roughness increases when raising material removal rate by raising feed rate singlely or raising depth of mill-grinding singlely; surface roughness has decreasing trend with raising material removal rate by increasing feed rate and depth of mill-grinding at the same time.

Research on the Vibration Tapping Performance of Particle Reinforced Aluminum Matrix Composites

2011 ◽  
Vol 189-193 ◽  
pp. 3198-3207 ◽  
Author(s):  
Hui Min Lu ◽  
De Yuan Zhang ◽  
Yang Liu
Keyword(s):  
Tool Life ◽  
Cutting Speed ◽  
Aluminum Matrix ◽  
Low Frequency ◽  
Aluminum Matrix Composites ◽  
Matrix Composites ◽  
Forward Angle ◽  
Dry Cutting ◽  
Backward Angle

The vibration tapping technology has been employed with success on some difficult-to-machine material such as titanium alloy, hardened steel and so on. However, there are very few studies on the application of the torsion vibration tapping in particle reinforced aluminum. The tapping performance of small size thread holes in particle reinforced aluminum matrix composites Al2O3p/Al and SiCp/Al during common tapping and low-frequency vibration tapping using high speed steal(HSS) machine-used taps is researched experimentally in this work. The influence of vibration parameters, e.g. cutting speed V, net forward angle of each stroke LT and times of repeat cutting Q on tapping torque, tool wear, tool life and quality of thread holes is investigated during the experimentation. The results show that the common vibration tapping with small amplitude, relatively high frequency and a lot of repeat cutting times suit to tap the Al2O3p/Al, whereas the step vibration tapping with large amplitude, relatively low frequency and a few repeat cutting times suit to tap the SiCp/Al due to difference performance of the two kinds of material. The influence of Q and LT on the quality of thread holes, tapping torque and tool life is sensitive on the Al2O3p/Al, whereas the influence of V and Q on the quality of thread holes, tool wear and tool life is sensitive on the SiCp/Al. Furthermore, the optimum vibration parameter in the Al2O3p/Al by dry cutting is cutting speed of 400r/min, net forward angle of each stroke of 1.5°, backward angle of each stroke of 45°. The optimum vibration parameter in SiCp/Al by dry cutting is cutting speed of 220r/min, net forward angle of each stroke of 420°, backward angle of each stroke of 430°. From the test results and micrographs, it was observed that the particle could be fractured on the surface finish on tapping processing. The proper vibration tapping parameter can void the adhesion in the tap flute, decrease the tapping torque, improve the quality of thread hole and prolong the tap life.

scholarly journals The Investigation of Machinability and Surface Properties of Aluminium Alloy Matrix Composites

2021 ◽  
Vol 53 (4) ◽  
pp. 210412
Author(s):  
Priyadarsini Morampudi ◽  
Venkata Ramana V.S.N. ◽  
Koona Bhavani ◽  
Amrita M ◽  
V Srinivas
Keyword(s):  
Surface Roughness ◽  
Aluminum Matrix ◽  
Stir Casting ◽  
Aluminum Matrix Composites ◽  
Al Alloy ◽  
Matrix Composites ◽  
Casting Method ◽  
Alloy Matrix ◽  
The Matrix ◽  
Aluminium Alloy Matrix

Aluminum matrix composites (AMCs) are crucial to the progress of composite application areas due to their remarkable mechanical properties. Their usage has expanded into different fields such as the aerospace, automobile, and defense industries. The present study used wrought Al alloy AA6061 as the matrix, while ilmenite (FeTiO3) particles were used as reinforcement at different weight percentages to prepare metal matrix composites. One of the most economical and simple casting routes among the several available fabrication techniques for the preparation of composites is the stir casting method, which was applied in the present investigation to prepare the AMCs. The machinability of the fabricated composites and the surface roughness property after machining were studied to understand the effect of speed and feed during machining. The results showed that an increase in speed decreased the cutting forces and the surface roughness. Meanwhile, an increase in surface roughness was observed with an increase in feed.

scholarly journals The Effectiveness of Reinforcement and Processing on Mechanical Properties, Wear Behavior and Damping Response of Aluminum Matrix Composites

2019 ◽  
Vol 38 (2019) ◽  
pp. 927-939 ◽  
Author(s):  
Fakhir Aziz Rasul Rozhbiany ◽  
Shawnim Rashied Jalal
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Aluminum Matrix Composites ◽  
Wear Loss ◽  
Matrix Composites ◽  
Damping Characteristics ◽  
Coated Carbide

AbstractMetal matrix composites are an essential product used in engineering materials. This product has wide applications in automotive, aerospace, and other uses because of their lower density, good specific strength, best machinability, and better mechanical properties compared to Al 6063 alloy. In this paper, four different reinforced such as (MA), (MCA), (NFC) and (SA) with a constant rate of 5 wt.% for each reinforced element used and mixed with Al 6063 alloy as a metal matrix composite by using modified two-step mechanical stirrer and having three blades at each step. Coated carbide tool insert was carrying out the turning process. Surface roughness measured after turning of every change in cutting speed. Average chip length and its shape style formation performed within cutting speeds of 10 and 90 m/min, which appears in different length and shapes. Mechanical properties, damping characteristics, and wear loss improved dramatically by adding all reinforced composites to the base Al 6063 alloys. As the results of experiments, the surface roughness decreased by adding all four types of reinforcements. The mechanical properties, wear loss and damping characteristics improved by the constituents of all kinds of reinforcements and also by mixing of all types of constituents together. The effects of MA and NFC are more compared to MCA and SA for improving all conditions of experimental results. Microstructure observation produces compact grain boundaries with strong grains of metal matrix composites compared to Al 6063 alloys.

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