Diamond tools wear in drilling of SiCp/Al matrix composites containing Copper

Xiang, Junfeng; Xie, Lijing; Gao, Feinong; Yi, Jie; Pang, Siqin; Wang, Xibin

doi:10.1016/j.ceramint.2017.12.154

Cited by 68 publications

(22 citation statements)

References 50 publications

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“…This is because the brittle SiC particles in the 2009Al matrix led to no significant softening effects in the 17vol.% SiC p /2009Al composites. Similar observations were also reported in [10,11] for the machining of SiC p /6061Al composites under different cutting parameters. Based on the above conclusions, to achieve high-quality turning operation with less edge defects and high dimensional accuracy, a smaller depth of cut and feed rate should be adopted in the turning of 17vol.% SiC p /2009Al composites, but in contrast, a high a spindle speed as possible should be employed.…”

Section: Locationsupporting

confidence: 89%

“…These studies revealed that the tool life considerably decreased with the increase of cutting speed and reinforced particle size. Several researchers [10][11][12] have analyzed the influence of tool materials and cutting parameters on surface roughness and subsurface damage when cutting SiC p /Al composites, and concluded that high cutting speeds and low feed rates produced higher surface quality, and if SiC particles were removed by pressed-into or cut-through mechanisms, good surface finish would have been achieved. Dabade et al [13] investigated the mechanism of chip formation during the cutting of SiC p /Al composites, and showed that both cutting speed and feed rate had a very significant influence on the chip segment.…”

Section: Introductionmentioning

confidence: 99%

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Experimental and Numerical Study of Edge Defects When Turning 17vol.% SiCp/2009Al Composites

Zhou

Xiang

et al. 2019

Applied Sciences

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In this work, a three-dimensional large-deformation thermo-elastic-plastic finite element model for oblique cutting was established to analyze edge defects during the machining of 17vol.% SiCp/2009Al composites. The formation process of edge defects at the workpiece exit during turning was investigated, and the influence of depth of cut, feed rate, and spindle speed on the edge defect sizes at the workpiece exit was explored. The results show that a negative deformation plane began to form as the cutting tool approached the exit end of cut, and the resultant cracks propagated towards the negative shear deformation plane, which led to workpiece edge defects. In addition, the size of edge defects increased with increasing depth of cut and feed rate, while the spindle speed had less influence on the size of edge defects. The numerical results of the effects of cutting parameters on edge defects were also compared to those of the turning experimental data, and were found to be in reasonable agreement.

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Section: Locationsupporting

confidence: 89%

Section: Introductionmentioning

confidence: 99%

Experimental and Numerical Study of Edge Defects When Turning 17vol.% SiCp/2009Al Composites

Zhou

Xiang

et al. 2019

Applied Sciences

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“…This is attributed to the fact that the hardness of the PCD is much higher than any of the reinforcement used in the development of metal matrix composites [21] and hence provides higher tool life compared to carbide tool. Besides, PCD tools are excellent for better surface integrity of the work materials at higher cutting speed and low feed rate [22]. Therefore, in the present study PCD and carbide insert were used to check the effect on surface integrity of newly developed aluminium metal matrix composite during turning operation.…”

Section: Effect Of Turning Parameters and Reinforcement On The Surfacmentioning

confidence: 99%

Effect of Turning Parameters and Reinforcement on the Surface Roughness of Hybrid Aluminium Metal Matrix Composite

Suthar,

Patel*

2019

IJEAT

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Since last two decades, technology has changed rapidly in each industry from consumer goods to aerospace. To quench the thrust of technology advancement of industries, the research community has to develop the novel materials. As a part of the ongoing process of material development and machinability study, present work was carried out to find out the effect of various cutting parameters on surface roughness and machining time of aluminium Hybrid Metal Matrix Composites (AHMMCs). In this study, pure aluminium was used as a matrix material while; B4C, Mg, Ti and Graphite were used as reinforcement. It was observed that 2202 RPM spindle speed, 0.18 mm/rev feed rate and 1.1 mm depth of cut are the optimum turning parameters with PCD insert. While machining of same composites using carbide insert, optimum spindle speed, feed rate and depth of cut are 2091 RPM, 0.19 mm/rev and 1.1 mm respectively. Moreover, PCD insert provides better surface finish compared to carbide coated insert for same cutting conditions. Moreover, the effect of reinforcement particles presence on the surface finish was also investigated and it was concluded that reinforcement presence reduces the surface roughness considerably. Particularly presence of Mg and graphite reduces surface finish significantly.

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“…The phase transformation of diamond into graphite during drilling of Al6063/SiC p /65p composites containing Cu is correlated to machining induced thermodynamics conditions with the catalysis of Cu in air atmosphere. The reciprocating actions of thin graphite layer formed by the oxidation of hydrogen chemisorbed on diamond surface with copper oxides and SiC particulates’ high-frequency scrape on newly-formed graphite film lead to the continual and significant occurrence of diamond graphitization [ 31 ]. More details of diamond tools wear during machining of SiC p /Al composites containing Cu is provided in [ 31 ].…”

Section: Experimental Workmentioning

confidence: 99%

Mechanism-Based FE Simulation of Tool Wear in Diamond Drilling of SiCp/Al Composites

et al. 2018

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The aim of this work is to analyze the micro mechanisms underlying the wear of macroscale tools during diamond machining of SiCp/Al6063 composites and to develop the mechanism-based diamond wear model in relation to the dominant wear behaviors. During drilling, high volume fraction SiCp/Al6063 composites containing Cu, the dominant wear mechanisms of diamond tool involve thermodynamically activated physicochemical wear due to diamond-graphite transformation catalyzed by Cu in air atmosphere and mechanically driven abrasive wear due to high-frequency scrape of hard SiC reinforcement on tool surface. An analytical diamond wear model, coupling Usui abrasive wear model and Arrhenius extended graphitization wear model was proposed and implemented through a user-defined subroutine for tool wear estimates. Tool wear estimate in diamond drilling of SiCp/Al6063 composites was achieved by incorporating the combined abrasive-chemical tool wear subroutine into the coupled thermomechanical FE model of 3D drilling. The developed drilling FE model for reproducing diamond tool wear was validated for feasibility and reliability by comparing numerically simulated tool wear morphology and experimentally observed results after drilling a hole using brazed polycrystalline diamond (PCD) and chemical vapor deposition (CVD) diamond coated tools. A fairly good agreement of experimental and simulated results in cutting forces, chip and tool wear morphologies demonstrates that the developed 3D drilling FE model, combined with a subroutine for diamond tool wear estimate can provide a more accurate analysis not only in cutting forces and chip shape but also in tool wear behavior during drilling SiCp/Al6063 composites. Once validated and calibrated, the developed diamond tool wear model in conjunction with other machining FE models can be easily extended to the investigation of tool wear evolution with various diamond tool geometries and other machining processes in cutting different workpiece materials.

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Diamond tools wear in drilling of SiCp/Al matrix composites containing Copper

Cited by 68 publications

References 50 publications

Experimental and Numerical Study of Edge Defects When Turning 17vol.% SiCp/2009Al Composites

Experimental and Numerical Study of Edge Defects When Turning 17vol.% SiCp/2009Al Composites

Effect of Turning Parameters and Reinforcement on the Surface Roughness of Hybrid Aluminium Metal Matrix Composite

Mechanism-Based FE Simulation of Tool Wear in Diamond Drilling of SiCp/Al Composites

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