Reinforcement and Cutting Tools Interaction during MMC Machining - A Review

2018 ◽  
Vol 22 ◽  
pp. 47-54 ◽  
Author(s):  
Mukesh Chaudhari ◽  
M. Senthil Kumar
Keyword(s):  
Tool Wear ◽  
Metal Matrix Composites ◽  
Process Parameters ◽  
Surface Finish ◽  
Metal Matrix ◽  
Cutting Tools ◽  
Tool Geometry ◽  
Matrix Composites ◽  
Good Surface ◽  
Aerospace Medical

Aluminum based metal matrix composites (AMMC) have found its applications in the automobile, aerospace, medical, and metal industries due to their superior mechanical properties. Fabricated Aluminum based metal matrix composites require machining to improve the surface finish and dimensional tolerance. Machining should be accomplished by good surface finish by consuming lowest energy and less tool wear. This paper reviews the machining of Aluminum based metal matrix composites to investigate the effect of process parameters such as tool geometry, tool wear, surface roughness, chip formation and also process parameters.

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.

An Experimental Determination of Optimum Processing Parameters for Al∕SiC Metal Matrix Composites Made Using Ultrasonic Consolidation

2007 ◽  
Vol 129 (4) ◽  
pp. 538-549 ◽  
Author(s):  
Y. Yang ◽  
G. D. Janaki Ram ◽  
B. E. Stucker
Keyword(s):  
Bond Strength ◽  
Metal Matrix Composites ◽  
Process Parameters ◽  
Metal Matrix ◽  
Oscillation Amplitude ◽  
Processing Parameters ◽  
Optimum Combination ◽  
Matrix Composites ◽  
Ultrasonic Consolidation ◽  
Push Out

Ultrasonic consolidation, an emerging additive manufacturing technology, is one of the most recent technologies considered for fabrication of metal matrix composites (MMCs). This study was performed to identify the optimum combination of processing parameters, including oscillation amplitude, welding speed, normal force, operating temperature, and fiber orientation, for manufacture of long-fiber-reinforced MMCs. A design of experiments approach (Taguchi L25 orthogonal array) was adopted to statistically determine the influences of individual process parameters. SiC fibers of 0.1mm diameter were successfully embedded into an Al 3003 metal matrix. Push-out testing was employed to evaluate the bond strength between the fiber and the matrix. Data from push-out tests and microstructural studies were analyzed and an optimum combination of parameters was achieved. The effects of process parameters on bond formation and fiber/matrix bond strength are discussed.

Experimental and Theoretical Investigations on Tool Wear and Surface Quality in Micro Milling of SiCp/Al Composites Under Dry and MQL Conditions

2018 ◽  
Author(s):  
Ben Deng ◽  
Haowei Wang ◽  
Fangyu Peng ◽  
Rong Yan ◽  
Lin Zhou
Keyword(s):  
Tool Wear ◽  
Metal Matrix Composites ◽  
Surface Quality ◽  
Wear Mechanism ◽  
Metal Matrix ◽  
High Stress ◽  
Micro Milling ◽  
Matrix Composites ◽  
Fe Simulations ◽  
Theoretical Investigations

During the machining processes of ceramic particle reinforced metal matrix composites, the severe tool wear constrains the quality and cost of the parts. This paper presents the experimental and theoretical investigations of the tool wear behavior and surface quality when micro milling the 45vol% SiCp/Al composites under dry and minimum quantity lubrication (MQL) conditions. The results of scanning electron microscope (SEM) and energy dispersive spectrometer (EDS) show that the wear mechanism of diamond coated micro mills are adhesive, abrasion, oxidization, chipping and tipping, even though it has been reported that abrasion is the most important tool wear mechanism when machining particle reinforced metal matrix composites. Compared with dry lubrication condition, the environmentally friendly MQL technique can enhance the tool life and surface roughness, and reduce the cutting force significantly under given cutting parameters. Then, finite element (FE) simulations are employed to investigate chip formation process in micro orthogonal cutting to reveal the effects of reinforced particle on tool wear and surface quality. The FE simulations shows the local high stress, hard reinforced particles in metal matrix, debonded and cracked particles are the key factors leading to the severe tool wear and the unsmoothed surface morphology.

Effect of process parameters on machining of Al -TiC metal matrix composites using RSM

2020 ◽  
Author(s):  
R. Pugazhenthi ◽  
D. Sreeram ◽  
Clement Tom Scaria ◽  
G. Anbuchezhiyan ◽  
P. Nanthakumar
Keyword(s):  
Metal Matrix Composites ◽  
Process Parameters ◽  
Metal Matrix ◽  
Matrix Composites

A Phenomenological Model for Tool Wear in Friction Stir Welding of Metal Matrix Composites

2013 ◽  
Vol 44 (8) ◽  
pp. 3757-3764 ◽  
Author(s):  
Tracie J. Prater ◽  
Alvin M. Strauss ◽  
George E. Cook ◽  
Brian T. Gibson ◽  
Chase D. Cox
Keyword(s):  
Friction Stir Welding ◽  
Tool Wear ◽  
Metal Matrix Composites ◽  
Phenomenological Model ◽  
Metal Matrix ◽  
Matrix Composites ◽  
Friction Stir
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