Tool Wear in Machining AlSi/AlN Metal Matrix Composite 10 Wt% Reinforcement Using Uncoated Cutting Tool

2013 ◽  
Vol 465-466 ◽  
pp. 973-977
Author(s):  
M.S. Said ◽  
M.S. Yusoff ◽  
C.H. Che Hassan ◽  
Mohd Asri Selamat ◽  
J.A. Shukur ◽  
...  
Keyword(s):  
Tool Wear ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Low Density ◽  
Industrial Sectors

Aluminum silicon (Al/Si) alloy, a metal matrix composite (MMC), is widely used in various industrial sectors, such as transportation, domestic equipment, aerospace, military, and construction. Al/Si alloy is a matrix composite reinforced with aluminum nitride (AlN) particle and transformed into a new-generation material for automotive and aerospace applications. AlN material is an advanced material characterized by light weight, high strength, and high hardness and stiffness, which makes it suitable for various future applications. However, its high ceramic particle reinforcement and the irregular nature of these particles along the matrix material make it a low density material. This low density is the main cause of problems during machining of this material. This paper studies tool wear in milling AlSi/AlN metal matrix composite by using an uncoated carbide cutting tool. The volume of AlN reinforced particle was 10%. The milling process was carried out under dry cutting conditions. The uncoated carbide insert parameters used were the following: cutting speed of 230 m/min to 370 m/min, feed rate of 0.4, 0.6, and 0.8 mm/tooth, and a corresponding depth of cut (DOC) of 0.3, 0.4, and 0.5 mm, respectively. Sometech SV-35 video microscope system was used for tool wear measurements. Results revealed that tool wear increases at 230 m/min cutting speed, 0.4 mm/tooth feed rate, and 0.3 mm depth of cut. The medium cutting speed, specifically the 300 m/min cutting speed, 0.4 mm/tooth feed rate, and 0.5 mm DOC, is the optimum condition for a longer tool life (82.94 min) and is ideal for cutting AlSi/AlN MMCs.

Tool Wear and Surface Roughness when Machining AlSi/AlN Metal Matrix Composite Using Uncoated Carbide Cutting Tool

2013 ◽  
Vol 773-774 ◽  
pp. 409-413 ◽  
Author(s):  
M.S. Said ◽  
J.A. Ghani ◽  
Che Hassan Che Haron ◽  
Shahrizan Yusoff ◽  
Mohd Asri Selamat ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Milling Process ◽  
Cutting Condition ◽  
Carbide Cutting Tool

Aluminium silicon alloy (AlSic) matrix composite reinforced with aluminium nitride (AlN) particle is a new generation material for automotive and aerospace application. This material has low density, light weight, high strength, high hardness and stiffness. Metal Matrix Composit (MMC) material is one of the advanced materials which have good future prospects. This paper presents the study of tool wear and surface roughness investigation when milling AlSi/AlN Metal Matrix Composite using uncoated carbide cutting tool. The volume of AlN reinforced particle was 10%. The milling process was carried out under dry cutting condition. The uncoated carbide insert parameters used were cutting speed of (250-750 m/min), while feed rate and depth of cut were kept constant at 0.15 mm/tooth of 0.3mm respectively. The Sometech SV-35 video microscope system and Mitutoyo surface roughness tester were used for tool wear measurements and surface roughness respectively. The results revealed that the tool wear increases with cutting speed (450 m/min). While at high cutting speed, the surface finish improves. It was found that the cutting speed of 750m/min was optimum condition for obtaining smooth finish and longer tool life. Keywords: AlSi/AlN Metal Matrix Composite milling process, tool wear, and surface roughness, uncoated cemented carbide tool

scholarly journals Mechanical Behavior and Microstructure Evolution of Al-5%Cu/TiC Metal Matrix Composite

2020 ◽  
Vol 23 (4) ◽  
pp. 252-255
Author(s):  
L. Ponraj Sankar ◽  
R. Kamalakannan ◽  
G. Aruna ◽  
M.R. Meera ◽  
V. Vijayan ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Wear Rate ◽  
Cutting Force ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Depth Of Cut

This paper aims to analyze the mechanical characteristics of Al-5%Cu/TiC metal matrix composite, like Surface Roughness, Tensile strength, wear rate of the cutting tool. Copper particles added with aluminum alloy, which can improve the machinability and also reduce wear rate. Typically the titanium materials prefer for its excellent strength during the load-carrying process. Here the TiC particles added with aluminum alloy to increase the composite hardness range. The casting samples are machined by the uncoated carbide cutting tool in CNC. The input turning parameters are speed, depth of cut, feed rate, and cutting force. The surface roughness measurement was done after the machining operation. The build-up edge and microstructure behavior of the tool and workpiece were analyzed using Scanning Electron Microscope. The result shows the more Built-up edge formed at low cutting speed and less build-up edge formed at low cutting speed. The higher cutting force indicates the lower cutting speed of 50m/min. The Build-up edges investigated at lower cutting speed and higher cutting speed. While adding TiC in Al-5%Cu, the elongation of MMC reduced, so it can able to increase the strength of the MMC specimen. Based on these results can able to predict the good mechanical and surface properties of metal matrix composite for the specific application.

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.

Chaotic Tool Wear During Machining of Titanium Metal Matrix Composite (TiMMCs)

2014 ◽  
Author(s):  
Xuan-Truong Duong ◽  
Marek Balazinski ◽  
René Mayer
Keyword(s):  
Mathematical Model ◽  
Tool Wear ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Tool Life ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Titanium Metal

The initial tool wear during machining of titanium metal matrix composite (TiMMCs) is the result of several wear mechanisms: tool layer damage, friction - tribological wear, adhesion, diffusion and brace wear. This phenomenon occurs at the first instant and extends to only ten seconds at most. In this case the adhesive wear is the most important mechanism while the brace wear is considered as a resistance wear layer at the beginning of the steady wear period. In this paper, the effect of the initial tool wear and initial cutting conditions on tool wear progression and tool life is investigated. We proposed herein a new mathematical model based on the scatter wear and Lyapunov exponent to study quantitatively the “chaotic tool wear”. The Chaos theory, which has proved efficient in explaining how something changes in time, was used to demonstrate the dependence of the tool life on the initial cutting conditions and thus contribute to a better understanding of the influence of the initial cutting condition on the tool life. Based on the chaotic tool wear model, the scatter wear dimension and Lyapunov exponents were found to be positive in all case of the initial cutting conditions such as initial speed, feed rate and depth of cut. The initial cutting speed appears however to have the most significant impact on tool life. In particular, the mathematical model was successfully applied to the case of machining TiMMCs. It was clearly shown that changing the initial cutting speed by 20 m/min for the first two seconds of machining instead of keeping it constant at 60 m/min during the whole cutting process leads to an increase in the tool life (up to 24%).

Tool Wear Analysis of Al 6061 Reinforced with 10 wt% Al2O3 Using High Hardened Inserts

2015 ◽  
Vol 787 ◽  
pp. 643-647
Author(s):  
M. Vignesh ◽  
K. Venkatesan ◽  
R. Ramanujam ◽  
Sundaravel Vijayan
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Stir Casting ◽  
Depth Of Cut ◽  
Machining Time ◽  
Al 6061 ◽  
Optimum Cutting ◽  
Coated Carbide

Metal matrix composites (MMC) are the combination of base metal matrix and reinforcing materials like SiC, Al2O3, etc. The present research is focused on the machinability studies of Al 6061 reinforced with 10% wtof Al2O3 particles using multi layered coated carbide inserts. Fabricated samples by stir casting route were turned by the most variable factors, cutting speed, depth of cutand by a constant feed rate of 0.206 mm/rev. Surface roughness and tool wear are considered asoutput. Experiments are conducted by varying the cutting speed while keeping feed rate and depth of cut as constant. After the optimum cutting speed was determined, the depth of cut is varied by keeping the cutting speedand feed rateas constant.Based on the optimum cutting speed (150 m/min), depth of cut (1.2 mm) and feed rate (0.206 mm/rev), a long run test was carried out to find out the tool life and surface finish. But due to the softness nature built up edge formation is obtained. At the optimal parametric combination, the built up edge obtained is less than 2 mm for a machining time of 425 s

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.

scholarly journals Investigation on cutting tool wear in turning Al 7075/SiCp metal matrix composite

2018 ◽  
Vol 377 ◽  
pp. 012110 ◽  
Author(s):  
Diptikanta Das ◽  
Anil Kumar Chaubey ◽  
Bijaya Bijeta Nayak ◽  
Purna Chandra Mishra ◽  
Chandrika Samal
Keyword(s):  
Tool Wear ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Cutting Tool ◽  
Cutting Tool Wear ◽  
Al 7075

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.

scholarly journals Milling Inconel 718 Workpiece With Cryogenically Treated And Untreated Cutting Tools

2021 ◽  
Author(s):  
Hüseyin Gürbüz ◽  
Şehmus Baday
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Abrasive Wear ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Tool Wear ◽  
Feed Force

Abstract Although Inconel 718 is an important material for modern aircraft and aerospace, it is a kind material, which is known to have low machinability. Especially, while these types of materials are machined, high cutting temperatures, BUE on cutting tool, high cutting forces and work hardening occur. Therefore, in recent years, instead of producing new cutting tools that can withstand these difficult conditions, cryogenic process, which is a heat treatment method to increase the wear resistance and hardness of the cutting tool, has been applied. In this experimental study, feed force, surface roughness, vibration, cutting tool wear, hardness and abrasive wear values that occurred as a result of milling of Inconel 718 material by means of cryogenically treated and untreated cutting tools were investigated. Three different cutting speeds (35-45-55 m/min) and three different feed rates (0.02-0.03-0.04 mm/tooth) at constant depth of cut (0.2 mm) were used as cutting parameters in the experiments. As a result of the experiments, lower feed forces, surface roughness, vibration and cutting tool wear were obtained with cryogenically treated cutting tools. As the feed rate and cutting speed were increased, it was seen that surface roughness, vibration and feed force values increased. At the end of the experiments, it was established that there was a significant relation between vibration and surface roughness. However, there appeared an inverse proportion between abrasive wear and hardness values. While BUE did not occur during cryogenically treated cutting tools, it was observed that BUE occurred in cutting tools which were not cryogenically treated.

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