scholarly journals Improvisation of Machining Parameters for Better Surface Finish of MMC Material using Taguchi Method

2021 ◽  
Vol 10 (5) ◽  
pp. 93-96
Author(s):  
Sandeep Suresh Patil ◽  
Harichandra K. Chavhan ◽  
Umesh U Patil ◽  
Nilesh Damodar Patel
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Tensile Strength ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Process Parameters ◽  
Surface Finish ◽  
Metal Matrix ◽  
Vital Role ◽  
Machining Parameters

Metal matrix composite is used in engineering applications due to its superior mechanical properties. MMC’s are reinforced with particle fiber, whisker, and particulate. The size of particulates used is classified as micro, nano, and macro. The particulate reinforced MMC’s have excellent form-ability compared to fiber and whisker composite. Metal matrix composite has outstanding wear, heat resistance, and excellent mechanical properties. Many authors have been stated the property as its ability of workpiece material to be machined or it refers to workpiece response to machining or it is normally applied to the machining properties of work material or it indicates how easily and fast a material can be machined. MMC materials are difficult to machine with a superior surface finish. In this study Al6061 with Silicon Carbide and Graphite are fabricated with 5 weight % using squeeze casting route. Tensile strength and hardness are tested according to ASTM standards and as a result, there was an increase in tensile strength and hardness of MMC. Machining process parameters plays a vital role in defining surface roughness. This machining parameters are to be optimized to get the better surface finish results. Taguchi techniques is used. To optimized the machining parameters affecting machining of MMC for surface roughness are identified. Orthogonal array L9 was selected based on three parameters with three levels.There is a vital role played by the feed rate in increasing the surface roughness of the material. Relevant process parameters considered for a better roughness of the surface are, cutting speed 300RPM, the rate of feed 0.13 mm/rev, and the depth of cut 0.4mm.

scholarly journals Experimentation on Mechanical Properties and Machinability of Al7075/Al2o3/Gr/Sic Metal Matrix Component

2020 ◽  
Vol 8 (5) ◽  
pp. 5024-5031
Keyword(s):  
Mechanical Properties ◽  
Impact Strength ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Surface Finish ◽  
Metal Matrix ◽  
Base Material ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
The Impact

Aluminum based metal matrix composite was prepared by stir casting process. Generally metal matrix composites are having some benefits due to the present’s reinforcement particles. Basically aluminum material does not have much strength, for increasing its strength and mechanical properties reinforcement particles are like SiC, Boron Carbide, Aluminum Oxide, Titanium Carbide, Fly Ash, Graphite added to base material. In this experiment 2.5% of Al2O3 , 5% of Graphite and 5% of Silicon Carbide are added toAl7075 (base material). The Microstructure of composite has been identified under optical microscope. Impact, Hardness, Tensile tests were conducted to find out the strength of the metal matrix composite. To find out the surface finish of composites after machining Taguchi method was adopted for the design of experiments and L9 Orthogonal array was taken to identify the optimum machining parameters affecting surface finish. In adding of 2.5% of Al2O3 , 5% of Gr and 5% of SiC the Impact Strength of Izod test is decreased by 23%, 30%, 46% and the Impact Strength of Charpy test is increased by 20%,-20%, and 20% respectively. The Brinell hardness value and Rockwell Hardness is increased by 9%, 3%, 28% and 9%, 1%, 6% respectively compare to the base material Al7075.Tensile Strength is decreased by 17%, 12%, 50% by adding of 2.5% of Al2O3 , 5% of Gr and 5% of SiC respectively compare to base alloy. The better surface finish is obtained at speed 1500 rpm, feed 0.05 mm/rev and 1 mm depth of cut for the materials Al7075.The lowest Tool Wear occurred for the material Al7075 at1000 rpm, feed at 0.05 mm/rev and depth of cut at 0.25.

scholarly journals Analysis, predictive modelling and multi-response optimization in electrical discharge machining of Al-22%SiC metal matrix composite for minimization of surface roughness and hole overcut

2020 ◽  
Vol 7 ◽  
pp. 20 ◽  
Author(s):  
Subhashree Naik ◽  
Sudhansu Ranjan Das ◽  
Debabrata Dhupal
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Discharge Current ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Parameters ◽  
Response Optimization ◽  
Pulse On Time

Due to the widespread engineering applications of metal matrix composites especially in automotive, aerospace, military, and electricity industries; the achievement of desired shape and contour of the machined end product with intricate geometry and dimensions that are very challenging task. This experimental investigation deals with electrical discharge machining of newly engineered metal matrix composite of aluminum reinforced with 22 wt.% of silicon carbide particles (Al-22%SiC MMC) using a brass electrode to analyze the machined part quality concerning surface roughness and overcut. Forty-six sets of experimental trials are conducted by considering five machining parameters (discharge current, gap voltage, pulse-on-time, pulse-off-time and flushing pressure) based on Box-Behnken's design of experiments (BBDOEs). This article demonstrates the methodology for predictive modeling and multi-response optimization of machining accuracy and surface quality to enhance the hole quality in Al-SiC based MMC, employing response surface methodology (RSM) and desirability function approach (DFA). Finally, a novel approach has been proposed for economic analysis which estimated the total machining cost per part of rupees 211.08 during EDM of Al-SiC MMC under optimum machining conditions. Thereafter, under the influence of discharge current several observations are performed on machined surface morphology and hole characteristics by scanning electron microscope to establish the process. The result shows that discharge current has the significant contribution (38.16% for Ra, 37.12% in case of OC) in degradation of surface finish as well as the dimensional deviation of hole diameter, especially overcut. The machining data generated for the Al-SiC MMC will be useful for the industry.

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.

Optimization of Machining Parameters on Turning of Hybrid Metal Matrix Composite

2013 ◽  
Vol 315 ◽  
pp. 113-116 ◽  
Author(s):  
T.S. Mahesh Babu ◽  
P.S. Ramkumar ◽  
Nambi Muthukrishnan
Keyword(s):  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Surface Finish ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Ratio Method ◽  
Depth Of Cut ◽  
Mechanical And Thermal Properties ◽  
Machining Parameters ◽  
Hybrid Metal Matrix Composite

Hybrid metal matrix composite constitutes a tough metal matrix with reinforcement of at least two ceramic particulates and exhibit superior mechanical and thermal properties. The difficulties in machining metal matrix composites are obtaining good surface finish, consumption of more electrical power, involving excessive cutting forces and greater tool wear as it contain very hard ceramic particulates. This factor restrict the wide spread application of these kind of materials. Hence the study of machining characteristics and the optimization of the cutting parameters are prime importance. In this paper aluminium alloy is taken as metal matrix and the silicon carbide (SiC 10% by wt.) and boron carbide (B4C 5% by wt.) taken as ceramic reinforcement. This material is fabricated in the form of cylindrical rod using stir casting method. Turning operations are carried out in medium duty lathe using poly crystalline diamond (PCD) cutting tool insert. Taguchis design of L09orthogonal array is followed selecting three machining factors namely cutting speed, feed and depth of cut at three levels. Optimal cutting conditions are arrived by Signal-Noise ratio method with respect to surface roughness. The results are validated by (ANOVA) analysis of variance and the percentage of contribution of cutting speed, feed rate and depth of cut for better surface finish are determined and it is found that the vital parameter is feed followed by cutting speed and then by depth of cut.

Experimental Investigation during Micro-Milling of Hybrid Al6063 MMC Reinforced with SiC and ZrO2

2019 ◽  
Vol 33 ◽  
pp. 1-9
Author(s):  
P. Tripathy ◽  
K.P. Maity
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Metal Matrix ◽  
Material Removal ◽  
Removal Rate ◽  
Micro Milling

The experimental investigation of process characteristics while performing micro-milling on hybrid aluminium metal matrix composite is discussed in this article. High Speed Steel micro end mill cutters are used for machining of micro-slots on Al6063 metal matrix composite reinforced with zirconia and silicon carbide. The tools are also treated cryogenically at -196°C using liquid nitrogen with a holding time of 24 hours. For this investigation, machining parameters like feed rate, cutting speed and depth of cut are considered as the process parameters. The effect of the process parameters on the material removal rate and surface roughness for hybrid metal matrix composite are analyzed. In addition, tools wear for untreated and cryo-treated single tempered tools are also investigated. The output responses i.e., material removal rate and surface roughness of cryo-treated tools exhibit better results than untreated tool due to increase in strength, hardness and wear resistance.

scholarly journals Investigations on Mechanical Behavior of Al6061-TiO2-SiC Produced by Stir Casting

2018 ◽  
Vol 7 (3.34) ◽  
pp. 369
Author(s):  
Nagendran N ◽  
Shanmuganathan V K ◽  
Gayathri N ◽  
Suresh K ◽  
Aravindh S ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Stir Casting ◽  
Mechanical And Thermal Properties ◽  
Matrix Composites ◽  
Casting Method ◽  
Structural Applications

Fine mechanical and thermal properties of metal matrix composites make them more demanding in various fields such as automotive, aerospace and structural applications. In this paper an effort has been made to fabricate a metal matrix composite, Titanium-di-oxide and silicon carbide reinforced in Al 6061 matrix using stir casting method. The reinforcements were added in 2%, 4% and 6% of weight to Al6061 to fabricate the metal matrix composite. Castings were machined and the specimens were prepared for various testing. Mechanical properties such as tensile strength, hardness, and corrosion analysis were studied for various compositions of reinforcements. And then the reinforcement was analyzed and studied for the improvement of mechanical properties in the material.  

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