scholarly journals Machining of Aluminums Alloys with the Addition of Reinforced Carbide Phase

2020 ◽  
Vol 60 (1) ◽  
pp. 11-20
Author(s):  
Piotr Putyra ◽  
Marcin Podsiadło ◽  
Lucyna Jaworska ◽  
Jolanta Laszkiewicz-Łukasik ◽  
Maciej Dyzia ◽  
...  
Keyword(s):  
Volume Fraction ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Aluminum Matrix ◽  
Polycrystalline Diamond ◽  
Cutting Parameters ◽  
Machining Parameters ◽  
Ceramic Phase ◽  
The Matrix ◽  
Longitudinal Turning

This paper presents the results of the processes of treating aluminum matrix casting materials with the addition of a ceramic phase. The matrix of the composite material was an Al-Si7 casting alloy with addition of 2 mass% Mg. The volume fraction of the reinforcing phase in the form of silicon carbide ranged from 5 to 15 vol.%. Preliminary machining tests were carried out at the Mori Seiki NL2000SY turning and milling center. The cutting properties were evaluated during longitudinal turning. Cutting tests were carried out using tools made of polycrystalline diamond, regular boron nitride, and cemented carbides. The nature of VBB wear was checked in accordance with PN-ISO 3685:1996. The influence of machining parameters (cutting speed, feed, cutting depth) on the value of cutting tools temperature was determined. An analysis of the chip shaping mechanism during machining was performed at various cutting parameters. The tests were carried out using the FLIR A655 thermal imaging camera and the fast Phantom MIRO M310 fast camera. Cast composite materials were also subjected to the processes of waterjet cutting, EDM cutting, and EDM drilling (EDM electro discharge machining).

Optimization of Drilling Process on Al-SiC Composite using Grey Relation Analysis

2015 ◽  
Vol 5 (4) ◽  
pp. 17-31 ◽  
Author(s):  
K. Vinoth Babu ◽  
M. Uthayakumar ◽  
J. T. Winowlin Jappes ◽  
T. P. D. Rajan
Keyword(s):  
Volume Fraction ◽  
Cutting Speed ◽  
Microscopy Study ◽  
Stir Casting ◽  
Experimental Result ◽  
Drilling Process ◽  
Machining Parameters ◽  
Casting Technique ◽  
The Matrix ◽  
Coated Carbide

This study reveals the multi objective optimization of machining parameters in drilling of SiC reinforced with aluminium metal matrix composites through grey relational analysis. The composite is prepared with varying volume fraction of the reinforcement by liquid metal stir casting technique. Uniform distribution of SiC particle in the matrix is witnessed through microscopy study and observed that the hardness and strength on different composite. The drilling experiments were performed with coated carbide tool with different point angle such as 90o, 120o and 140o. Cutting speed, feed, point angle and volume fraction are considered as input parameters and the performance characteristics such as surface roughness and thrust force are observed as output response in this study. The significant contributions of these factors are determined using Analysis of Variance (ANOVA). The optimized process parameters have been validated by the confirmation test. The experimental result shows that point angle influences more on output performance followed by feed and cutting speed.

Optimization of Drilling Process on Al-SiC Composite Using Grey Relation Analysis

2017 ◽  
pp. 392-406
Author(s):  
K. Vinoth Babu ◽  
M. Uthayakumar ◽  
J. T. Winowlin Jappes ◽  
T. P. D. Rajan
Keyword(s):  
Volume Fraction ◽  
Cutting Speed ◽  
Microscopy Study ◽  
Stir Casting ◽  
Experimental Result ◽  
Drilling Process ◽  
Machining Parameters ◽  
Matrix Composites ◽  
Casting Technique ◽  
The Matrix

This study reveals the multi objective optimization of machining parameters in drilling of SiC reinforced with aluminium metal matrix composites through grey relational analysis. The composite is prepared with varying volume fraction of the reinforcement by liquid metal stir casting technique. Uniform distribution of SiC particle in the matrix is witnessed through microscopy study and observed that the hardness and strength on different composite. The drilling experiments were performed with coated carbide tool with different point angle such as 90o, 120o and 140o. Cutting speed, feed, point angle and volume fraction are considered as input parameters and the performance characteristics such as surface roughness and thrust force are observed as output response in this study. The significant contributions of these factors are determined using Analysis of Variance (ANOVA). The optimized process parameters have been validated by the confirmation test. The experimental result shows that point angle influences more on output performance followed by feed and cutting speed.

scholarly journals Study on Technological Effects of a Precise Grooving of AlSi13MgCuNi Alloy with a Novel WCCo/PCD (DDCC) Inserts

Materials ◽  
2020 ◽  
Vol 13 (11) ◽  
pp. 2467 ◽  
Author(s):  
Szymon Wojciechowski ◽  
Rafał Talar ◽  
Paweł Zawadzki ◽  
Stanisław Legutko ◽  
Radosław Maruda ◽  
...  
Keyword(s):  
Tool Life ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Fold Increase ◽  
Cutting Parameters ◽  
Cemented Carbide ◽  
Machining Parameters ◽  
Tungsten Carbides ◽  
Machined Surface ◽  
Cutting Path

The WCCo/PCD (Diamond Dispersed Cemented Carbide—DDCC) manufactured with the use of PPS (pulse plasma sintering) are modern materials intended for cutting tools with the benefits of tungsten carbides and polycrystalline diamonds. Nevertheless, the cutting performance of DDCC materials are currently not recognized. Thus this study proposes the evaluation of technological effects of a precise groove turning process of hard-to-cut AlSi13MgCuNi alloy with DDCC tools. The conducted studies involved the measurements of machined surface topographies after grooving with different cutting parameters. In addition, the tool life and wear tests of DDCC inserts were conducted during grooving process and the obtained results were compiled with values reached during machining with cemented carbide tools. It was also proved that grooving of AlSi13MgCuNi alloy with DDCC inserts enables 5 times longer tool life and almost 3-fold increase of cutting path compared to values obtained during grooving with H3 and H10 cemented carbide inserts. Ultimately, the feed value of f = 0.15 mm/rev and cutting speed in a range of 800 m/min ≤ vc ≤ 1000 m/min during grooving with DDCC inserts can be defined as an optimal machining parameters, enabling the maximization of tool life and improvement in surface quality.

Investigation of the Machinability Characteristics of GFRP / Epoxy Composites Using Taguchi Methodology

2014 ◽  
Vol 612 ◽  
pp. 123-129
Author(s):  
Hari Vasudevan ◽  
Naresh Deshpande ◽  
Ramesh Rajguru
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Polycrystalline Diamond ◽  
Cutting Parameters ◽  
Industrial Applications ◽  
Woven Fabric ◽  
Depth Of Cut ◽  
Taguchi Methodology ◽  
Longitudinal Turning

Many glass fiber reinforced plastic (GFRP) composite components made from primary melt processes require additional machining to meet the requirements of assembly and accurate dimensional tolerances. Importance of woven fabric based glass fibre reinforced composites is widely known in many industrial applications. However, very little is known about machinability of these composites. Cutting force is treated as one of the primary measures for determining the machinability of any material.This paper presents an investigation into the longitudinal turning of woven fabric and epoxy based GFRP composites, using polycrystalline diamond tool, so as to analyze the effect of cutting parameters and insert radius on the cutting force. The force was measured through longitudinal turning, according to the experimental plan, as developed on the basis of Taguchi methodology. The signal to noise ratio and analysis of variance were applied to the experimental data, in order to determine the effect of the process variables on tangential cutting force. Statistical results indicated that the cutting force is significantly influenced (at a 95% confidence level) by feed rate, followed by depth of cut, whereas, cutting speed and insert radius have a smaller influence. The cutting force also increases with the increase in feed rate and depth of cut.

Optimization of Surface Roughness in Turning Operation Using Firefly Algorithm

2015 ◽  
Vol 815 ◽  
pp. 268-272 ◽  
Author(s):  
Nur Farahlina Johari ◽  
Azlan Mohd Zain ◽  
Noorfa Haszlinna Mustaffa ◽  
Amirmudin Udin
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Firefly Algorithm ◽  
Volume Fraction ◽  
Optimization Problems ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machining Time

Recently, Firefly Algorithm (FA) has become an important technique to solve optimization problems. Various FA variants have been developed to suit various applications. In this paper, FA is used to optimize machining parameters such as % Volume fraction of SiC (V), cutting speed (S), feed rate (F), depth of cut (D) and machining time (T). The optimal machining cutting parameters estimated by FA that lead to a minimum surface roughness are validated using ANOVA test.

Investigation on Peaming Process of PCD Tool when Reaming Aluminium Cast Alloys

2011 ◽  
Vol 381 ◽  
pp. 30-33
Author(s):  
Yong Guo Wang ◽  
Biao Tian ◽  
Xiang Ping Yan ◽  
Jiong Yi Song
Keyword(s):  
Experimental Investigation ◽  
Fourier Transform ◽  
Fast Fourier Transform ◽  
Real Time ◽  
Cutting Speed ◽  
Polycrystalline Diamond ◽  
Cutting Parameters ◽  
Hole Diameter ◽  
Machining Parameters ◽  
Cast Alloys

An experimental investigation on the unique reaming behavior of aluminium cast alloys (AlSi12) by using PCD (polycrystalline diamond) tools has been studied. The torque has been monitored in real time during reaming process and the average values of torque were calculated by using FFT (Fast Fourier Transform) filtering. The optimized cutting parameters are provided in terms of analyzing the cutting torque, hole diameter and cylindricity. Results show that the torque initial increases with the rising cutting speed but subsequently decreases when the cutting speed reach to 6000r/min. It is also notable that the optimization of machining parameters basing on cylindricity are that when the cutting speed is under 6000r/min, smaller cutting feed is recommended, while when the cutting speed is over 6000r/min, higher cutting feed is appropriate.

Evaluation of Tool Wear when Milling SiCp/Al Composites

2010 ◽  
Vol 455 ◽  
pp. 226-231 ◽  
Author(s):  
Shu Tao Huang ◽  
Li Zhou
Keyword(s):  
Tool Wear ◽  
Large Particle ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Aluminum Matrix ◽  
High Volume ◽  
High Volume Fraction ◽  
Aluminum Matrix Composites

The research on wear mechanism and characteristics of tool is a key issue for machining silicon carbide particle reinforced aluminum matrix composites (SiCp/Al). The machining adaptability, wear characteristics of the cermet cutting tools, TiN-coated tools and cemented carbide tools have been studied while milling SiCp/Al composites with large particle and high volume fraction. The results indicate that the wear resistance of the three kinds of tools are almost the same during machining large particle, high volume fraction SiCp/Al composite, and the tool wear is mainly presented as flank wear, which is caused by the mechanical wear of SiC particles. The wear rate of tools increases with increasing the cutting speed, but the difference is not very obvious. However, no matter high-speed cutting or low-speed cutting, the tool will be seriously worn in short distance. The each tooth cutter feed rate and depth of cutting have little effect on the tool wear.

Effects of Machining Parameters on the Microhardness of Chips

1989 ◽  
Vol 111 (3) ◽  
pp. 220-228 ◽  
Author(s):  
V. K. Jain ◽  
S. Kumar ◽  
G. K. Lal
Keyword(s):  
Shear Strain ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Shear Angle ◽  
Interface Temperature ◽  
Machining Parameters ◽  
Machining Conditions ◽  
Temperature Shear ◽  
Longitudinal Turning ◽  
Microhardness Tester

It has been found that the shear strain acceleration governs the machining parameters like tool-chip interface temperature, shear angle, tool wear, etc. It is therefore speculated that microhardness of the chips for the same machining conditions but for different shear strain accelerations would be different. To test this hypothesis, experiments have been conducted using mild steel as work material and cemented carbide bits as cutting tools. Experiments were performed in two ways: longitudinal turning and accelerated cutting. Chips were collected at the same machining conditions but at different shear strain acceleration. Microhardness of the chips has been measured using the Leibtz-microhardness tester and the results have been analyzed using a computer program CADEAG-1. Using the responses (i.e., microhardness), mathematical models have been evolved. Effects of different parameters (cutting speed, feed, etc.) on the microhardness of the chips in all the three cases (i.e., longitudinal turning, facing, and taper turning) have been studied. It has been concluded that the microhardness of the chips obtained during accelerated cutting is governed by the shear strain acceleration and its governing parameters.

Cutting Performance and Wear Mechanism of Si3N4-Based Nanocomposite Ceramic Tool

2010 ◽  
Vol 443 ◽  
pp. 324-329 ◽  
Author(s):  
Bin Zou ◽  
Chuan Zhen Huang ◽  
Han Lian Liu ◽  
Jin Peng Song
Keyword(s):  
Wear Resistance ◽  
Wear Mechanism ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Performance ◽  
Nano Particles ◽  
Ceramic Tool ◽  
Tool Materials ◽  
High Cutting Speed ◽  
The Matrix

Si3N4/TiN nanocomposite tool and Si3N4/Ti(C7N3) nanocomposite tool were prepared. The cutting performance and wear mechanism of Si3N4-based nanocomposite ceramic tool was investigated by comparison with a commercial sialon ceramic tool in machining of 45 steel. Si3N4-based nanocomposite ceramic tool exhibits the better wear resistance than sialon at the relatively high cutting speed. The increased cutting performance of Si3N4-based nanocomposite ceramic tool is ascribed to the higher mechanical properties. Nano-particles can refine the matrix grains and improve the bonding strength among the matrix grains of Si3N4-based nanocomposite ceramic tool materials. It contributes to an improved wear resistance of the cutting tools during machining.

The Application of FEA in High-Speed Cutting

2011 ◽  
Vol 287-290 ◽  
pp. 104-107
Author(s):  
Lian Qing Ji ◽  
Kun Liu
Keyword(s):  
High Speed ◽  
Feeding Rate ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Material Model ◽  
Friction Model ◽  
Cutting Depth ◽  
High Speed Cutting ◽  
Key Technologies

The history and application of the FEA are briefly presented in this paper. Several key technologies such as the building of material model, the establishment of the chip - tool friction model as well as meshing are described. Taking the high-speed cutting of titanium alloy (Ti - 10V - 2Fe - 3Al) as an example , reasonable cutting tools and cutting parameters are determinted by simulating the influences of cutting speed, cutting depth and feeding rate on the cutting parameters using FEA.

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