scholarly journals Aluminum-Based MMC Machining with Carbide Cutting Tool

2016 ◽  
Vol 686 ◽  
pp. 149-154
Author(s):  
István Szalóki ◽  
Sándor Sipos ◽  
Zsolt János Viharos
Keyword(s):  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Matrix Composites ◽  
Pressure Infiltration ◽  
Milling Parameters ◽  
Coated Carbide ◽  
Rapid Tool

Cutting of metal matrix composites (MMCs) has been considerably difficult due to the extremely abrasive nature of the reinforcements causing rapid tool wear and high machining cost. In this experimental study, three aluminium-based metal matrix composites (MMCs) were produced using a high pressure infiltration. Machining tests were carried out by face milling on the MMCs using coated carbide (HM) cutting tool at various values of feed rate, width of cut and depth of cut, under a constant cutting speed. The effect of the varied parameters on the surface roughness was investigated. The obtained results indicate that the Rz and Rp parameters are more capable to describe the influence of the milling parameters on the surface quality.

Evaluation of the Surface Integrity when Machining LM6 Aluminum Metal Matrix Composites Using Coated and Uncoated Carbide Cutting Tools

2013 ◽  
Vol 465-466 ◽  
pp. 1049-1053 ◽  
Author(s):  
Abu Bakar Mohd Hadzley ◽  
Ahmad Siti Sarah ◽  
Raja Abdullah Raja Izamshah ◽  
Amran Ali Mohd ◽  
Mohd Shahir Kasim ◽  
...  
Keyword(s):  
Metal Matrix Composites ◽  
Surface Integrity ◽  
Feed Rate ◽  
Metal Matrix ◽  
End Milling ◽  
Cutting Tools ◽  
Depth Of Cut ◽  
Matrix Composites ◽  
Radial Depth ◽  
Coated Carbide

Metal matrix composite is composite material that combines the metallic properties of matrix alloys and additional element to reinforce the product. This paper evaluates the machining performance of uncoated carbide and coated carbide in terms of surface integrity during end milling of LM6 aluminium MMC. The parameter of cutting speed, feed rate and axial depth of cut were kept constant at 3000 rpm spindle speed, 60 mm/min feed rate and 0.5 axial dept of cut. The radial depth of cut were varied from 0.01mm to 0.1 mm. The results indicated that uncoated carbide show the better performance in terms of surface roughness and surface profile, as compared to coated carbide. On the other hand, coated carbide cutting tools suffered with built-up-edge formation at the tool edge, hence caused shearing effect and deterioration at the tool-chip interface. This study is expected to provide understanding of machining metal matrix composites based materials.

Surface integrity in machining of AZ91/SiC composites

2021 ◽  
pp. 095440622110179
Author(s):  
A Asgari ◽  
M Sedighi
Keyword(s):  
Metal Matrix Composites ◽  
Surface Integrity ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Depth Of Cut ◽  
Matrix Composites ◽  
Machined Surface ◽  
Sic Particles ◽  
Finished Surface

Use of metal matrix composites (MMC) is growing due to their high strength-to-weight ratio, resistance to wear, creep, etc. Machining of metal-matrix composites (MMC) faces many challenges, especially with regard to obtaining a finished surface with high quality. In this research, AZ91/SiC samples with different volume fractions are machined at different cutting conditions with respect to feed rate, cutting speed, and depth of cut. Surface integrity of the machined samples is analyzed by different methods such as tactile profilometer and 3D surface topography to investigate the SiC effects on the finished surface. Additionally, sample surfaces are evaluated by scanning electron microscope (SEM) and with energy-dispersive X-ray (EDS) to assess the surface defects formed around reinforcement materials. Results indicate SiC particles decline the surface quality and uniformity due to the formation of some defects such as micro cracks, holes, and undesired deformations when the cutting process. Also, subsurface SiC particles close to the machined surface are cracked after machining.

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.

Experimental Studies on Machinability of 14 wt.% of SiC Particle Reinforced Aluminium Alloy Composites

2012 ◽  
Vol 723 ◽  
pp. 94-98 ◽  
Author(s):  
Sheng Qin ◽  
Xiao Jiang Cai ◽  
Yu Sheng Zhang ◽  
Qing Long An ◽  
Ming Chen
Keyword(s):  
Metal Matrix Composites ◽  
Metal Matrix ◽  
End Milling ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Matrix Composites ◽  
Coated Carbide ◽  
Coated Carbide Tools ◽  
Aluminium Metal

Since metal matrix composites (MMCs) have increasing applications in industries, this paper presents an experimental investigation on machinability of SiCp reinforced aluminium metal matrix composites. 14 wt.% of SiCp reinforcement addition composite was studied in end milling using CVD coated carbide tools under different cutting parameters. By experimental results, the relationships of cutting force and surface roughness with cutting speed and feed were discussed. Some defects concerning surface topography such as ploughed furrow, pits, matrix tearing, etc. were examined by SEM.

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.

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.

Optimization of machining parameters using WASPAS and MOORA

2019 ◽  
Vol 17 (2) ◽  
pp. 237-246 ◽  
Author(s):  
Venkateshwar Reddy Pathapalli ◽  
Veerabhadra Reddy Basam ◽  
Suresh Kumar Gudimetta ◽  
Madhava Reddy Koppula
Keyword(s):  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Metal Cutting ◽  
Optimal Parameter ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Matrix Composites ◽  
Content Type ◽  
Composite Samples

Purpose Nowadays, the applications of metal matrix composites are tremendously increasing in engineering fields. Consequently, the demand for precise machining of composites has also grown enormously. The purpose of this paper is to reduce production cost and simultaneously improve desired product quality through optimal parameter setting using WASPAS and MOORA. Design/methodology/approach Metal matrix composites were fabricated using stir casting process, with aluminum 6063 as matrix and titanium carbide as reinforcement. Fabricated composite samples were machined on medium duty lathe using cemented carbide tool. All the experiments were carried out based on Box–Behnken design. Comparison of multi objective optimization based on ratio analysis and weighted aggregated sum product assessment in optimizing four parameters, namely, “cutting speed,” “feed rate,” “depth of cut” and “reinforcement weight percent of composite samples”; evaluating their influence on material removal rate, cutting force and surface roughness were carried out. Findings The output achieved by both MOORA and WASPAS are in similar MCDM) techniques in the selection of machining parameters. Practical implications The results obtained in the present paper will be helpful for decision makers in manufacturing industries, who work in metal cutting area, to select the suitable levels for the parameters by implementing the MCDM techniques. Originality/value The novelty of this paper is making an attempt to select better MCDM technique based on the comparison of results obtained for the individual technique.

scholarly journals The Effectiveness of Reinforcement and Processing on Mechanical Properties, Wear Behavior and Damping Response of Aluminum Matrix Composites

2019 ◽  
Vol 38 (2019) ◽  
pp. 927-939 ◽  
Author(s):  
Fakhir Aziz Rasul Rozhbiany ◽  
Shawnim Rashied Jalal
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Aluminum Matrix Composites ◽  
Wear Loss ◽  
Matrix Composites ◽  
Damping Characteristics ◽  
Coated Carbide

AbstractMetal matrix composites are an essential product used in engineering materials. This product has wide applications in automotive, aerospace, and other uses because of their lower density, good specific strength, best machinability, and better mechanical properties compared to Al 6063 alloy. In this paper, four different reinforced such as (MA), (MCA), (NFC) and (SA) with a constant rate of 5 wt.% for each reinforced element used and mixed with Al 6063 alloy as a metal matrix composite by using modified two-step mechanical stirrer and having three blades at each step. Coated carbide tool insert was carrying out the turning process. Surface roughness measured after turning of every change in cutting speed. Average chip length and its shape style formation performed within cutting speeds of 10 and 90 m/min, which appears in different length and shapes. Mechanical properties, damping characteristics, and wear loss improved dramatically by adding all reinforced composites to the base Al 6063 alloys. As the results of experiments, the surface roughness decreased by adding all four types of reinforcements. The mechanical properties, wear loss and damping characteristics improved by the constituents of all kinds of reinforcements and also by mixing of all types of constituents together. The effects of MA and NFC are more compared to MCA and SA for improving all conditions of experimental results. Microstructure observation produces compact grain boundaries with strong grains of metal matrix composites compared to Al 6063 alloys.

Comparison of machining characteristics of metal matrix composites using CO2 laser curve cutting process

2017 ◽  
Vol 232 (3) ◽  
pp. 349-368 ◽  
Author(s):  
Vikas Sharma ◽  
Vinod Kumar
Keyword(s):  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Morphological Changes ◽  
Cutting Speed ◽  
Matrix Composites ◽  
Composites Materials ◽  
Input Variables ◽  
Output Characteristics ◽  
Metal Matrix Composite Material ◽  
Machining Characteristics

In the present work, the effects of input variables of laser beam machining on the machining characteristics of the metal matrix composites reinforced with SiC, Al2O3, and ZrO2 particles were investigated. The comparison of the machining characteristics has been done to analyze the behavior of various reinforced particles with the variation of laser machining variables. Various output characteristics such as dross height, kerf deviation, and striations angle have been investigated and compared with each metal matrix composite material. Parameters such as cutting speed, reinforced particles, and cut profile were found to be the most significant factors influencing the various output characteristics. The morphological changes in the structure have been examined using scanning electron microscopy and X-ray diffraction technique for the agglomeration of the reinforced particles. The crack and recast layer formation has been examined in the specimens of higher quantity of the reinforced particles. It was analyzed that the metal matrix composites material reinforced with SiC particles has shown different behaviors as compared to other metal matrix composites materials.

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