Investigation of Cutting Model in Machining of Al/SiCp Metal Matrix Composite

2011 ◽  
Vol 117-119 ◽  
pp. 1465-1470
Author(s):  
Sayed Mohamad Nikouei ◽  
Mohammad Ali Kouchakzadeh ◽  
R. Yousefi ◽  
M.A. Kadivar
Keyword(s):  
Chip Formation ◽  
Cutting Forces ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Shear Plane ◽  
Good Method ◽  
Depth Of Cut ◽  
Machining Forces ◽  
Experimental Cutting ◽  
Cutting Model

Prediction of shear plane angle is a way for prediction of the mechanism of chip formation, machining forces and so on. In this study, Merchant and Lee-Shaffer theories are used to predict the shear plane angles and cutting forces in machining of Al/SiCpMMC. The experimental cutting forces are compared with the calculated cutting force based on shear plane angles extracted from Merchant and Lee-Shaffer theories. The variation of these cutting forces with cutting speed, feed rate and depth of cut has been discussed. The results show that Merchant theory may be used as a good method for prediction of chip formation in machining of Al/SiCpMMC.

Cutting Model in Machining of Al/SiCp Metal Matrix Composite

2011 ◽  
Vol 410 ◽  
pp. 291-297
Author(s):  
Sayed Mohamad Nikouei ◽  
R. Yousefi ◽  
Mohammad Ali Kouchakzadeh ◽  
M.A. Kadivar
Keyword(s):  
Chip Formation ◽  
Cutting Forces ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Shear Plane ◽  
Good Method ◽  
Depth Of Cut ◽  
Machining Forces ◽  
Experimental Cutting ◽  
Cutting Model

Prediction of shear plane angle is a way for prediction of the mechanism of chip formation, machining forces and so on. In this study, Merchant and Lee-Shaffer theories are used for prediction of shear plane angles and cutting forces in machining of Al/SiCpMMC with 20% of SiC as reinforcement particles. The experimental cutting forces are compared with the calculated cutting force based on shear plane angles extracted from Merchant and Lee-Shaffer theories. The variation of these cutting forces with cutting speed, feed rate and depth of cut has been discussed. The results showed that Merchant theory may be used as a good method for prediction of chip formation in machining of Al/SiCpMMC.

scholarly journals Surface Quality and Chip Formation in Turning of LM6 Aluminium Alloy and Particulate Reinforced Metal Matrix Composite

2013 ◽  
Vol 773-774 ◽  
pp. 894-901
Author(s):  
Muhammad Yusuf ◽  
M.K.A. Ariffin ◽  
N. Ismail ◽  
S. Sulaiman
Keyword(s):  
Surface Roughness ◽  
Aluminium Alloy ◽  
Surface Quality ◽  
Chip Formation ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Cutting Condition

Majority of the components of aerospace and automotive vehicles need different machining operations, mainly for the assembly requirements. The components have to present both high dimensional precision and surface quality. This present work is concerned with the effect of cutting parameters (cutting speed, feed rate and depth of cut) on the surface roughness and the chip formation in turning process. The machining results are compared with LM6 aluminium alloy and TiC reinforced metal matrix composite under the same cutting conditions and tool geometry. The cutting condition models designed based on the Design of Experiments Response Surface Methodology. The objective of this research is to obtaining the optimum cutting parameters to get a better surface quality and also the chip formation and furthermore does not hazardous to the worker and the machined products quality. Results shows that Surface roughness values of LM6-TiC composite are higher as compared LM6 alloy at similar cutting condition. With increasing in cutting speed improves the surface quality. The surface quality increases with decrease of the feed rate and the depth of cut. There are difference chip forms for LM6 aluminium alloy and Al-TiC composite for a similar of cutting condition. Generally, chip formations of both materials are acceptable and favourable for the worker as well as the products and the tools.

Experimental and Numerical Machining of AA 5083

2011 ◽  
Vol 189-193 ◽  
pp. 4419-4424
Author(s):  
Behnam Davoodi ◽  
Mohammad Bagher Momeni ◽  
Mohammad Reza Eslami
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Chip Formation ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Simulation Software ◽  
Constitutive Law ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Element Modeling

The experimental machining and finite element modeling of 2D turning of AA5083 is presented. The ABAQUS/Explicit machining simulation software is applied for the finite element modeling. The experimental orthogonal machining for were conducted to investigate the effects of various machining parameters on chip morphology, machined surface condition, and resulting cutting forces. The measured cutting forces was compared to finite element modeling results with good agreement. The effects of cutting speed and rack angle of tool cutting factor for productivity in AA5083 machining, depth of cut, on the peak tool temperature are investigated. 2D Finite Element Model (FEM) of chip formation process, set up with an Arbitrary Lagrangian-Eulerian (ALE) formulation, proposed in the software ABAQUS/Explicit .the thermo-viscoplastic behavior of the workpiece material is modeled by the Johnson-Cook (JC) constitutive law. This study explores the use of experimental and finite element modeling to study the cutting force. Results of this research help to guide the design of new cutting tool materials and coatings and the studies of chip formation to further advance the productivity of AA5083 machining.

Chip Formation and Cutting Performance Investigation on Titanium Alloy Machining

2011 ◽  
Vol 264-265 ◽  
pp. 1062-1072
Author(s):  
Shen Yung Lin ◽  
Y.Y. Cheng ◽  
C.T. Chung
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Chip Formation ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Cutting Performance ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Chip Type ◽  
Cutting Model

First, a 2D orthogonal cutting model for titanium alloy is constructed by finite element method in this study. The cutting tool is incrementally advanced forward from an incipient stage of tool-workpiece engagement to a steady state of chip formation. Cockroft and Latham fracture criterion [1] is adopted as a chip separation criterion. By changing the settings of cutting variables such as cutting speed, depth of cut and tool rake angle to investigate the chip formation process and the variation of cutting performance during titanium cutting simulation. The changes of chip type, cutting force, effective stress/strain and cutting temperature with different cutting condition combinations are thus analyzed. The result demonstrates that the serrated chip type is obviously produced when cutting titanium alloy. Next, water-based and oil-based cutting fluids are employed in conjunction with proper cutting parameter arrangements to perform up-milling experiments. By measuring the cutting force, surface roughness and tool wear to investigate the effect of these combinations of milling variables on the variation of cutting performance for Ti-6Al-4V. The chip shape and cutting force obtained from the experiment are compared with those calculated from simulation. It is shown that there is a good agreement between simulation and experimental results.

scholarly journals Research on Chip Formation Mechanism and Surface Morphology of Particle-reinforced Metal Matrix Composites

2021 ◽  
Author(s):  
Yuxin Fang ◽  
Youqiang Wang ◽  
Ping Zhang ◽  
Heng Luo
Keyword(s):  
Surface Topography ◽  
Metal Matrix Composites ◽  
Chip Formation ◽  
Cutting Forces ◽  
Metal Matrix ◽  
Complex Stress ◽  
Matrix Composites ◽  
Machined Surface ◽  
Failure Evolution ◽  
Cutting Model

Abstract In this paper, a finite element (FE) cutting model for particle-reinforced metal matrix composites (PRMMCs) considering material damage was developed to predict SiC particle failure, cutting forces and machined surface topography in SiCp/Al composite machining, and to analyze the dynamic mechanisms of chip formation and particle failure evolution. The validity of the simulation model was verified by comparing the simulation results with the cutting forces and surface topography obtained from the milling machining experiments. It was found that complex stress-strain fields exist in SiCp/Al composites with mesoscopic non-homogeneous structures, and alternating reticulation of tensile and compressive stress between particles was observed; particle failure due to tool-workpiece interaction exists in both direct and indirect ways; particle failure and local chip deformation during machining affect surface topography and chip shaping, resulting in serrated chips, pitting on the machined surface, and residual particle fragments.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

Statistical Analysis of Process Parameters in Drilling of Al/Al2O3p Metal Matrix Composites

2014 ◽  
Vol 14 (3) ◽  
pp. 171-175 ◽  
Author(s):  
Yashvir Singh ◽  
Amneesh Singla ◽  
Ajay Kumar
Keyword(s):  
Surface Roughness ◽  
Statistical Analysis ◽  
Process Parameters ◽  
Metal Matrix ◽  
Design Method ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Signal To Noise ◽  
Drilling Parameters

AbstractThis paper presents a statistical analysis of process parameters for surface roughness in drilling of Al/Al2O3p metal matrix composite. The experimental studies were conducted under varying spindle speed, feed rate, point angle of drill. The settings of drilling parameters were determined by using Taguchi experimental design method. The level of importance of the drilling parameters is determined by using analysis of variance. The optimum drilling parameter combination was obtained by using the analysis of signal-to-noise ratio. Through statistical analysis of response variables and signal-to-noise ratios, the determined significant factors are depth of cut and drill point angle with the contributions of 87% and 12% respectively, whereas the cutting speed is insignificant contributing by 1% only. Confirmation tests verified that the selected optimal combination of process parameter through Taguchi design was able to achieve desired surface roughness.

Predictive Modeling and Optimization of Cutting Forces Through RSM and Taguchi Techniques in the Turning of ASTM B574 (Hastelloy C-22)

2018 ◽  
pp. 398-417
Author(s):  
İsmail Kırbaş ◽  
Musa Peker ◽  
Gültekin Basmacı ◽  
Mustafa Ay
Keyword(s):  
Feed Rate ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Orthogonal Experimental Design ◽  
Depth Of Cut ◽  
Effective Parameters ◽  
Factors Affecting ◽  
The Impact

In this chapter, the impact of cutting parameters (depth of cut, cutting speed, feed, flow, rake angle, lead angle) on cutting forces in the turning process with regard to ASTM B574 (Hastelloy C-22) material has been investigated. Variance analysis has been applied in order to determine the factors affecting the cutting forces. The optimization of the parameters affecting the surface roughness has been obtained using response surface methodology (RSM) based on the Taguchi orthogonal experimental design. The accuracy of the developed models required for the estimation of the force values (Fx, Fy, Fz) is quite successful. In this study, where the R2 value has been used as the criterion/measure, accuracy values of 93.35%, 95.03%, and 95.09% have been achieved for Fx, Fy, and Fz, respectively. As a result of the ANOVA analysis, the most effective parameters for Fx at a 95% confidence interval are depth of cut, feed rate, flow, and rake angle. The most effective parameter for Fy is depth of cut, while the most effective parameters for Fz are depth of cut, feed rate, and flow, respectively.

Surface Roughness and Chip Formation of AlSi/AIN Metal Matrix Composite by End Milling Machining using the Taguchi Method

2014 ◽  
Vol 68 (4) ◽  
Author(s):  
M. S. Said ◽  
J. A. Ghani ◽  
R. Othman ◽  
M. A. Selamat ◽  
N. N. Wan ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Matrix Composite ◽  
Surface Finish ◽  
Chip Formation ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Taguchi Optimization ◽  
Cutting Speeds

The purpose of this research is to demonstrate surface roughness and chip formation by the machining of Aluminium silicon alloy (AlSic) matrix composite, reinforced with aluminium nitride (AlN), with three types of carbide inserts present. Experiments were conducted at various cutting speeds, feed rates, and depths of cut, according to the Taguchi method, using a standard orthogonal array L9 (34). The effects of cutting speeds, feed rates, depths of cut, and types of tool on surface roughness during the milling operation were evaluated using Taguchi optimization methodology, using the signal-to-noise (S/N) ratio. The surface finish produced is very important in determining whether the quality of the machined part is within specification and permissible tolerance limits. It is understood that chip formation is a fundamental element that influences tool performance. The analysis of chip formation was done using a Sometech SV-35 video microscope. The analysis of results, using the S/N ratio, concluded that a combination of low feed rate, low depth of cut, medium cutting speed, and an uncoated tool, gave a remarkable surface finish. The chips formed from the experiment varied from semi–continuous to discontinuous. 

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.

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