Investigation of tool wear and surface roughness during machining of ZA43–SiCp composite using full factorial approach

Marigoudar, Rajaneesh N.; Sadashivappa, K.

doi:10.1177/0954405413479478

Cited by 13 publications

(7 citation statements)

References 32 publications

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“…10 An increased amount of SiC reinforcement resulted in a higher tool-work interface temperature and higher cutting forces. A study on the machinability of a ZA43 alloy reinforced with SiC particles (size: 60 mm; 5-15 wt%) during dry turning by uncoated and coated carbides 11 showed that the cutting speed, feed rate and depth of cut affected both surface finish and tool wear.…”

Section: Introductionmentioning

confidence: 99%

Effect of machining parameters on the surface finish of a metal matrix composite under dry cutting conditions

Boswell

Islam

Davies

et al. 2015

Proceedings of the Institution of Mechanical Engineers, Part B:

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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 mm, 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.

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Section: Introductionmentioning

confidence: 99%

Effect of machining parameters on the surface finish of a metal matrix composite under dry cutting conditions

Boswell

Islam

Davies

et al. 2015

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…A parameter that represents the material properties can be defined by dividing the hardness by the elongation. Therefore, a three-factor, full-factorial design 15,16 methodology was used to investigate the influences of the material hardness and elongation, spindle speed and feed rate on the fractal dimension and surface roughness of the finished surface. The advantages of a full-factorial analysis include the greater amount of information provided, more accurate experimental results and more reliable conclusions.…”

Section: Methodsmentioning

confidence: 99%

Estimation of fractal dimension and surface roughness based on material characteristics and cutting conditions in the end milling of carbon steels

Zuo

Zhu

Zhou

et al. 2015

Proceedings of the Institution of Mechanical Engineers, Part B:

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Cutting parameters and material properties have important effects on the quality of milled surface, which can be characterized by fractal dimension and surface roughness. The relationships between two surface parameters (surface roughness and fractal dimension) and material hardness, elongation, spindle speed and feed rate were investigated, respectively, in this study. Four carbon steels, that is, AISI 1020, Gr 50, 1045 and 1566, were milled with five spindle speeds and four feed rates on a computer numerical control machine. The surface topographies were measured with a three-dimensional profiler. The surface profiles were obtained by re-sampling the data points on the surface topography in the measurement direction. The surface roughness and fractal dimension were calculated from the two-dimensional profiles, where the fractal dimension was obtained by the root-mean-square method. The results showed that for specific spindle speed and feed rate, the roughness of the milled surface decreased with the workpiece hardness, whereas the elongation and fractal dimension increased with the hardness. Based on the material hardness and elongation, spindle speed and feed rate, empirical formulae were established to quantitatively estimate the surface roughness and fractal dimension. Moreover, the spindle speed and feed rate can be easily calculated from the empirical formulae to achieve a surface with the desired surface roughness and fractal dimension. The empirical formulae have been demonstrated with the experiments and were shown to be applicable in estimating the surface roughness and fractal dimension for all carbon steels in end milling. The results are instructive for the fractal dimension estimation of the machined surfaces of carbon steel, which has not been previously studied.

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“…9 Research works into improving or quantifying the machinability of MMCs that has been undertaken since the early 1970s. [10][11][12][13] This is especially useful since carbide inserts are cheaper, and tool wear starts relatively quickly, allowing the evaluation of different parameters in order to determine their machinability and suitability for critical conditions. This is also ideal for evaluating the effects of cooling methods under similar conditions.…”

Section: Introductionmentioning

confidence: 99%

On the impacts of cutting parameters on surface roughness, tool wear mode and size in slot milling of A356 metal matrix composites reinforced with silicon carbide elements

Saberi

Niknam

Hashemi

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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Metal matrix composite is made of non-metallic reinforcements (usually ceramic) in metal matrices that are widely used in various industries, including aerospace and automotive. Two main components of metal matrix composite are the matrix (base metal) and the reinforcing particles that tend to increase the hardness of the workpart. The production and machining of such materials are hard and costly. However, due to their excellent mechanical properties such as high strength to weight ratio, high hardness and rigidity, corrosion resistance, abrasion resistance, and low thermal coefficient, their applications are still growing in various aspects. One major division of metal matrix composite is aluminum metal matrix composite with ceramics particulate reinforcement such as silicon carbide and alumina. According to review of literature, a low volume of information was found in terms of machinability of specific grades of aluminum composite (A356-10% silicon carbide) under various lubrication modes. Therefore, in the course of this study, several blocks of aluminum metal matrix composite (A356) reinforced with 10% silicon carbide elements were used under dry, minimum quantity lubrication and wet milling operation. The maximum flank wear, tool wear modes, as well as the average surface roughness were recorded and were subsequently studied as the machining performance attributes. The use of lubricants in both minimum quantity lubrication and wet modes led to reduced tool wear as compared with readings made under dry mode. However, under similar experimental conditions, no significant improvement was observed on the average surface roughness values.

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Investigation of tool wear and surface roughness during machining of ZA43–SiCp composite using full factorial approach

Cited by 13 publications

References 32 publications

Effect of machining parameters on the surface finish of a metal matrix composite under dry cutting conditions

Effect of machining parameters on the surface finish of a metal matrix composite under dry cutting conditions

Estimation of fractal dimension and surface roughness based on material characteristics and cutting conditions in the end milling of carbon steels

On the impacts of cutting parameters on surface roughness, tool wear mode and size in slot milling of A356 metal matrix composites reinforced with silicon carbide elements

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