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.

On the Optimisation Into Wire Electro-Discharge Machining of Al/Al2O3P Composites

2007 ◽  
Author(s):  
N. G. Patil ◽  
P. K. Brahmankar ◽  
L. G. Navale
Keyword(s):  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Kerf Width ◽  
Feed Speed ◽  
Machining Parameters ◽  
Matrix Composites ◽  
Electro Discharge Machining ◽  
Pulse On Time ◽  
Machining Parameter

Non-traditional process like wire electro-discharge machining (WEDM) is found to show a promise for machining metal matrix composites (MMCs). However, the machining information for the difficult-to-machine particle-reinforced material is inadequate. This paper is focused on experimental investigation to examine the effect of electrical as well as nonelectrical machining parameters on performance in wire electro-discharge machining of metal matrix composites (Al/Al2O3p). Taguchi orthogonal array was used to study the effect of combination of reinforcement, current, pulse on-time, off-time, servo reference voltage, maximum feed speed, wire speed, flushing pressure and wire tension on kerf width and cutting speed. Reinforcement percentage, current, on-time was found to have significant effect on cutting rate and kerf width. The optimum machining parameter combinations were obtained for cutting speed and kerf width separately.

Optimization in Hot Turning of Nickel Based Alloy Using Desirability Function Analysis

2016 ◽  
Vol 24 ◽  
pp. 64-70 ◽  
Author(s):  
A.K. Parida ◽  
K.P. Maity
Keyword(s):  
Feed Rate ◽  
Function Analysis ◽  
Desirability Function ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Cutting Velocity ◽  
Nickel Based Alloy ◽  
Desirability Function Analysis ◽  
Hot Turning

This paper presents a desirability function approach in order to find out an optimal combination of Machining parameters for multi-response parameters in hot turning operation of nickel based alloy. Taguchi’s L9 orthogonal array is used for experimental design. The machining parameters such as cutting velocity, feed rate, depth of cut and temperature are optimized by multi-response considerations namely power, flank wear, and MRR. ANOVA test was carried out and it was found that cutting speed is most influence parameter followed by feed rate, depth of cut and workpiece temperature. The optimization of machining parameters was found at 5.8 m/min of cutting speed, 30 °C preheating temperature, 0.2 mm depth of cut and 0.15 mm/rev feed rate

Effect of SiCp Reinforcement on Machinability of A356 Alloy Metal Matrix Composites

2016 ◽  
Vol 852 ◽  
pp. 142-148
Author(s):  
K. Jayakumar
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composites ◽  
Metal Matrix ◽  
End Milling ◽  
Cutting Speed ◽  
A356 Alloy ◽  
Experimental Result ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Matrix Composites

Machining of Aluminum Metal Matrix Composites (AMMCs) is a challenge for manufacturing industries due to their heterogeneous constituents which vary from soft matrix to hard reinforcements and their interfaces. To overcome the difficulties in machining of MMCs, researchers are continuously working to find the optimum process or machining parameters. In this work, End milling studies were carried out in A356 alloy powder-SiC particles (1 μm) in 0, 5, 10, 15 volume % reinforced AMMCs synthesised by vacuum hot pressing (VHP) route.The influence of machining parameters such as cutting speed, feed and depth of cut on the prepared composites in terms of surface roughness (Ra) and material removal rate (MRR) are measured from experimental study. Experiments were conducted as per Taguchi L16 orthogonal array with 4 factors and 4 levels.From the experimental result, it was identified that surface roughness varied from 0.214 μm to 4.115 μm and MRR varied from minimum of 1.11 cm3/min to maximum of 9.65 cm3/min. It is also observed that, MRR increased with increase in machining parameters and reinforcement quantity. Similarly, surface roughness decreased for increase of cutting speed, SiC particle (SiCp) reinforcement and increased for increase in feed and depth of cut. The optimum condition were observed in higher speed, lower feed and higher depth of cut on MMC with higher SiC content (15%) for getting higher machinability.

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.

Multi-Response Optimization in Turning of AA6061 T6 Using Desirability Function Analysis

2015 ◽  
Vol 812 ◽  
pp. 124-129 ◽  
Author(s):  
P. Jayaraman ◽  
L. Mahesh Kumar
Keyword(s):  
Function Analysis ◽  
Removal Rate ◽  
Desirability Function ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Multiple Responses ◽  
Ideal Approach ◽  
Response Optimization ◽  
Desirability Function Analysis

This paper presents an ideal approach for the optimization of machining parameters on turning of AA6061 T6 aluminium alloy with multiple responses based on orthogonal array with desirability function analysis. In this study, turning parameters namely cutting speed, feed rate and depth of cut are optimized with the considerations of multiple responses such as surface roughness (Ra), roundness (Ø) and material removal rate (MRR). Multi response optimization of machining parameters was done through desirability function analysis. The optimum machining parameters have been identified by a composite desirability value obtained from desirability function analysis. The performance index and significant contribution of process parameters were determined by analysis of variance.

Studies on Mechanical and Machinability Properties of B4Cp Reinforced 6061Aluminum MMC Produced via Melt Stirring

2014 ◽  
Vol 592-594 ◽  
pp. 744-748 ◽  
Author(s):  
Vijaykumar Hiremath ◽  
S.T. Dundur ◽  
Raj L. Bharath ◽  
G.L. Rajesh ◽  
V. Auradi
Keyword(s):  
Boron Carbide ◽  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Matrix Composites ◽  
Mechanical And Physical Properties ◽  
Aluminum Metal Matrix Composites ◽  
Poly Crystalline Diamond

Aluminum boron carbide metal matrix composites (Al-MMC) have got wide applications in aeronautical and automobile industries due to their excellent mechanical and physical properties. Due to the presence of harder reinforcement particles, machining of these composites is a difficult task. The results of experimental investigation on mechanical and machinability properties of Boron carbide particle (B4Cp) reinforced aluminum metal matrix composites are presented in this paper.The influence of reinforced ratio of 7 wt% of B4Cpon mechanical properties was examined. It was observed that addition of B4Cpreinforcement resulted in improvement in hardness and tensile strengths to the extent of 71% and 38.4% respectively. Fabricated samples were turned on medium duty lathe of 3 kW spidle power with Poly crystalline diamond tool (PCD) of 10 μm particle size at various cutting conditions. The effect of machining parameters, e.g. cutting speed, feed rate and depth of cut on cutting forces and formation of BUE was studied.

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