Tool Wear in High Speed Milling of SiCp/Al2024 Metal Matrix Composites

2010 ◽  
Vol 33 ◽  
pp. 200-203 ◽  
Author(s):  
Y.J. Wang ◽  
Ming Zhou ◽  
S.N. Huang ◽  
Y.J. Zhang
Keyword(s):  
Tool Wear ◽  
Metal Matrix Composites ◽  
Metal Matrix ◽  
High Speed ◽  
Flank Wear ◽  
Cutting Speed ◽  
Dominant Factor ◽  
Matrix Composites ◽  
High Speed Milling ◽  
Coated Tools

This paper presents an experimental study in high speed milling of metal matrix composites (MMCs). Machining tests were carried out on a high speed milling machine by using TiAlN coated tools and chemical vapour deposition (CVD) diamond coated tools. The cutting tool wear was investigated using an optical microscope and a scanning electron microscope (SEM). The experimental results showed that flank wear is the dominant tool wear mode and abrasive wear and adhesive wear appears to be the main wear mechanism. The build-up edge (BUE) exists during the machining process at a certain speeds. Cutting speed is a dominant factor affecting the flank wear. Generally, high cutting speed lead to severe tool wear, but there seemed to be a certain cutting speed which will cause the least tool wear. Furthermore, there exists a cutting speed limit for both TiAlN coated tools and CVD coated diamond tools in high speed milling of MMCs, beyond which the edge chipping will cause the tool failure very soon.

Simulation of High Speed Milling of SiCp/Al Metal Matrix Composites Based on Deform

2013 ◽  
Vol 589-590 ◽  
pp. 100-105
Author(s):  
Ke Ru Jiao ◽  
Shu Tao Huang ◽  
Li Fu Xu ◽  
Li Zhou
Keyword(s):  
Metal Matrix Composites ◽  
Metal Matrix ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Transient Temperature ◽  
Matrix Composites ◽  
High Speed Milling ◽  
Pcd Tools

By 3D finite element simulation for temperature field and tool wear of SiCp/Al metal matrix composites under the condition of high speed milling, we draw a conclusion that the most significant influence on cutting temperature is cutting speed, less is feed rates, the minimum is cutting depth, which is exactly the same as the influence law of ordinary metal cutting. In the course of high-speed milling SiCp/Al by PCD tools, the higher the cutting speed is, the bigger wearing depth of tools is. When v=300m/min, ap=0.5 mm, f=0.3 mm/r, the transient temperature in the milling would reach to 619°C. Such a high temperature can cause graphitizing wear of the PCD tools. Because of the effectiveness of the simulation’s conclusion, it is vital significance to the reasonable options of cutting parameters and the prolongation of tool life.

Flank Wear Progression During Machining Metal Matrix Composites

2005 ◽  
Vol 128 (3) ◽  
pp. 787-791 ◽  
Author(s):  
S. Kannan ◽  
H. A. Kishawy ◽  
M. Balazinski
Keyword(s):  
Tool Wear ◽  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Flank Wear ◽  
Tool Geometry ◽  
Matrix Composites ◽  
Proposed Model ◽  
Three Body Abrasion ◽  
Three Body ◽  
Bar Turning

The machining of composites present a significant challenge to the industry. The abrasive reinforcements cause rapid tool wear and increases the machining cost. The results from machining metal matrix composites (MMCs) with conventional tools show that the main mechanism of tool wear includes two-body abrasion and three-body abrasion. A more flexible method that can be considered as a cost-saving technique is therefore sought for studying the machinability characteristics of these materials. In the previous paper, a methodology for predicting the tool flank wear progression during bar turning of MMCs was presented (Kishawy, Kannan, and Balazinski, Ann. CIRP, 54/1, pp. 55–59). In the proposed model, the wear volume due to two-body and three-body abrasion mechanisms was formulated. Then, the flank wear rate was quantified by considering the tool geometry in three-dimensional (3D) turning. Our main objective in this paper is to validate the proposed model by conducting extensive bar turning experiments under a wide range of cutting conditions, tool geometries, and composite material compositions. The cutting test results showed good agreement between predicted and measured tool wear progression.

Advances in High-Speed Milling of Metal Matrix Composites

2012 ◽  
Vol 499 ◽  
pp. 9-14
Author(s):  
Ying Fei Ge ◽  
Jiu Hua Xu ◽  
Y.C. Fu ◽  
S. Zhang ◽  
W.L. Bian
Keyword(s):  
Metal Matrix Composites ◽  
Surface Quality ◽  
Tool Life ◽  
Metal Matrix ◽  
High Speed ◽  
Cutting Parameters ◽  
Matrix Composites ◽  
Machined Surface ◽  
High Speed Milling ◽  
Machined Surface Quality

Particle reinforced metal matrix composites (PMMC) possess many outstanding properties and are increasingly applied in automobile, aerospace, electronics and medical industries. However, PMMC is a typical difficult-to-machining material due to the rapid tool wear rate and excessive machining induced defects. Although large amount of investigations have been done on the conventional machining of PMMC, merely several researchers have dedicated themselves to the study of milling, especially high speed milling of this material. Within the milling studies, most researchers have selected the carbide coated or uncoated solid carbide tools whose tool life was not satisfactory for engineering application. The literatures review indicates that most researchers limited their study to sintering or casting SiCp/Al composites at the low or moderate cutting speed. Material produced by the in-situ reaction method or titanium matrix composites was seldom selected as the research object. The research content was limited to the effect of cutting parameters on the machined surface quality or cutting forces. It is suggested that high-speed milling with PCD tool should be conducted in order to improve the machined surface quality and material removal rate and decrease the machining cost. Tool life modeling, surface roughness prediction, cutting parameters optimization and high-speed milling data base and the expert system should be greatly noticed by the researchers.

Study on High-Speed Milling of Steam Turbine Blade Materials - Differences in Cutting Characteristics of an Unforged Ingot and a Forged Part of Stainless Steel

2017 ◽  
Vol 749 ◽  
pp. 3-8
Author(s):  
Tomonori Kimura ◽  
Takekazu Sawa ◽  
Tatsuyuki Kamijyo
Keyword(s):  
Stainless Steel ◽  
Tool Wear ◽  
Steam Turbine ◽  
High Speed ◽  
Flank Wear ◽  
Turbine Blades ◽  
Cutting Speed ◽  
High Speed Milling ◽  
Finished Surface ◽  
Steam Turbine Blade

Stainless steel is an excellent material that has properties such as heat and corrosion resistance. Thus, stainless steel is used as a material in steam turbine blades. Steam turbine blades are mainly manufactured using two methods. One is the cutting of unforged metal ingots. Another is the cutting of forged parts. Small blades are made by cutting metal ingots. Large blades are made by cutting forged parts. The mechanical characteristics of a metal ingot and a forged part, such as hardness and toughness, are almost the same. There were not researches related to a relationship between “an unforged ingot and a forged part of stainless steel” and “the differences of the tool wear and the finished surface by high-speed milling”.In this study, the high-speed milling of stainless steel was attempted for high-efficiency cutting of a steam turbine blade. The differences of the tool wear and the finished surface in the cuttings of an unforged ingot and a forged part were investigated. In the experiment, the cutting tool was a TiAlN coating radius solid end mill made of cemented carbide. The diameter of the end mill was 5 mm, and the corner radius was 0.2 mm. The cutting speed were 100 m/min-600 m/min. The workpieces used were a metal ingot and a forged part of stainless steel. In the results, it was found that the differences of the tool wear and the finished surface in the cuttings of an unforged ingot and a forged part. In the case of the unforged ingot, the flank wear became large with increasing cutting speed. On the other hand, in the case of forged part, the flank wear rapidly increased at a cutting speed of 100 m/min. In addition, the flank wear became smaller than the cutting speed 100 m/min at the cutting speed 200 m/min. Further, the flank wear became large with increasing cutting speed at cutting speeds higher than 200 m/min. That is, the flank wear was at a minimum at a cutting speed of 200 m/min. Although it could not be confirmed the characteristic of high speed milling at an unforged ingot, it has been identified at a forged part.

The Influence of SiC Particles on Tool Wear in Machining of Al/SiC Metal Matrix Composites Produced by Powder Extrusion

2011 ◽  
Vol 325 ◽  
pp. 393-399 ◽  
Author(s):  
R. Yousefi ◽  
M.A. Kouchakzadeh ◽  
J. Rahiminasab ◽  
M.A. Kadivar
Keyword(s):  
Tool Wear ◽  
Metal Matrix Composites ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Test Method ◽  
Engineering Properties ◽  
Depth Of Cut ◽  
Matrix Composites ◽  
Sic Particles

Metal matrix composites (MMCs) have received considerable attention due to their excellent engineering properties. However, poor machinability has been the main deterrent to their substitution for metal parts. The hardness and abrasive nature of reinforcement phase causes rapid tool wear during machining which results in high machining costs. In this study, the effect of SiC particles (5, 15 & 20 percent) on tool wear in turning process is experimentally investigated. Continuous dry turning of Al/SiC particulate metal matrix composite produced by powder metallurgy and utilizing titanium carbide inserts has been achieved as the test method. The influence of machining parameters, e.g. cutting speed, feed rate and depth of cut on tool wear and cutting forces were investigated during the experiments. The results show that tool wear increases with increasing cutting speed, depth of cut and feed rate. The cutting speed and depth of cut are more dominant factors compared to feed rate on the tool wear. In addition, it is concluded that the flank wear increases with the increase of SiC percentage in the MMC.

Optimization of Machining Hybrid Metal Matrix Composites Using Desirability Analysis

2014 ◽  
Vol 875-877 ◽  
pp. 1412-1420 ◽  
Author(s):  
R.R. Jai Preetham ◽  
Joel Morris ◽  
Kaushik Rajasekaran
Keyword(s):  
Tool Wear ◽  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Function Analysis ◽  
Desirability Function ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Matrix Composites ◽  
Hybrid Metal Matrix Composites ◽  
Desirability Function Analysis

This paper presents the detailed discussions on fabrication of Aluminium - silicon carbide (10% by weight of particles) and boron carbide (5% by weight of particles) Hybrid Metal Matrix Composites (Al/SiC/B4C MMC) using stir casting method. SiC and a B4C particle range from 30μm to 50 μm. The cylindrical rods of diameter 60 mm and length 250 mm are fabricated and subsequently machined using medium duty lathe of 2 kW spindle power to study the machinability issues of Hybrid MMC using Poly Crystalline Diamond (PCD) insert of 1600 grade. The optimum machining parameters have been identified by a composite desirability value obtained from desirability function analysis as the performance index, and significant contribution of parameters can then be determined by analysis of variance. Confirmation test is also conducted to validate the test result. Experimental results have shown that machining performance can be improved effectively through this approach. Results show at higher cutting speeds, good surface finish is obtained with faster tool wear. It is concluded that, tool wear and cutting force are directly proportional to the cutting speed, where as surface roughness is inversely proportional to the cutting speed. Percentage of error obtained between experimental value and predicted value is within the limit.

scholarly journals Machining of Titanium Metal Matrix Composites: Progress Overview

Materials ◽  
2020 ◽  
Vol 13 (21) ◽  
pp. 5011
Author(s):  
Cécile Escaich ◽  
Zhongde Shi ◽  
Luc Baron ◽  
Marek Balazinski
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanisms ◽  
Metal Matrix ◽  
Dust Emission ◽  
Cutting Speed ◽  
Matrix Composites ◽  
Titanium Metal ◽  
Machining Processes ◽  
Tool Wear Mechanisms

The TiC particles in titanium metal matrix composites (TiMMCs) make them difficult to machine. As a specific MMC, it is legitimate to wonder if the cutting mechanisms of TiMMCs are the same as or similar to those of MMCs. For this purpose, the tool wear mechanisms for turning, milling, and grinding are reviewed in this paper and compared with those for other MMCs. In addition, the chip formation and morphology, the material removal mechanism and surface quality are discussed for the different machining processes and examined thoroughly. Comparisons of the machining mechanisms between the TiMMCs and MMCs indicate that the findings for other MMCs should not be taken for granted for TiMMCs for the machining processes reviewed. The increase in cutting speed leads to a decrease in roughness value during grinding and an increase of the tool life during turning. Unconventional machining such as laser-assisted turning is effective to increase tool life. Under certain conditions, a “wear shield” was observed during the early stages of tool wear during turning, thereby increasing tool life considerably. The studies carried out on milling showed that the cutting parameters affecting surface roughness and tool wear are dependent on the tool material. The high temperatures and high shears that occur during machining lead to microstructural changes in the workpiece during grinding, and in the chips during turning. The adiabatic shear band (ASB) of the chips is the seat of the sub-grains’ formation. Finally, the cutting speed and lubrication influenced dust emission during turning but more studies are needed to validate this finding. For the milling or grinding, there are major areas to be considered for thoroughly understanding the machining behavior of TiMMCs (tool wear mechanisms, chip formation, dust emission, etc.).

Sign in / Sign up

Export Citation Format

Share Document