Investigation on characterization and machinability of Al-4032/SiC metal matrix composite

Saini, Pardeep; Singh, Premlata

doi:10.1088/2051-672x/ac5de4

Cited by 10 publications

(11 citation statements)

References 32 publications

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“…Saini and Singh [17] studied the end milling of Al-4032/3%SiC MMC using a carbide cutter The occurrence of hard reinforcement in base Al-alloy makes the MMC difficult to machine. But machining turns relatively easier at high cutting speed and low feed rate, resulting in improved surface finish.…”

Section: Research Backgroundmentioning

confidence: 99%

“…Earlier studies on fabrication and characterization of Al-4032/SiC composites reveal that the 6% reinforcement can be quite useful for the development of the AMCs with homogeneous microstructure and improved mechanical properties [17,20]. Therefore, in current research, the fabrication, morphological examination, mechanical characterization, and machining investigation has been attempted for Al-4032/6%SiC composite.…”

Section: Motivation For the Researchmentioning

confidence: 99%

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Effect of machining parameters on surface roughness and energy consumption during end milling of stir cast Al-4032/6%SiC composite

Saini¹,

Singh²

2022

Surf. Topogr.: Metrol. Prop.

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The machining of metal matrix composite (MMC) presents a significant challenge to the industry. The hard and abrasive nature of the reinforcement causes rapid tool wear and high machining cost. In the present research, Al-4032 based composite with 6% of SiC by weight has been fabricated by stir casting setup. Optical micrographs (OM) and scanning electron microscopy (SEM) with energy dispersive x-ray analysis (EDXA) have been used for the examination of the composite morphological, surface topography, and fracture behavior. Mechanical characterization i.e., testing of the composite for tensile strength, micro-hardness and impact strength has also been carried out. Cutting speed, feed rate and depth of cut are the cutting parameters selected to examine the responses—surface finish and energy consumption. The response surface methodology (RSM) based desirability approach has been employed to obtain the best combination of parameters for achieving the desired objectives. The result established that the inclusion of SiC in the base matrix demonstrates improved mechanical properties and a better-machined surface with optimized machining parameters. Multi-response optimization shows that the minimum surface roughness (0.99 μm) and minimum energy consumption (0.17 kWh) during end milling of Al-4032/6%SiC composite have been achieved at cutting speed 199 m min−1, feed rate 500 mm min−1 and depth of cut 0.50 mm. The confirmation experiments show good agreement between the predicted and measured responses.

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Section: Research Backgroundmentioning

confidence: 99%

Section: Motivation For the Researchmentioning

confidence: 99%

Effect of machining parameters on surface roughness and energy consumption during end milling of stir cast Al-4032/6%SiC composite

Saini¹,

Singh²

2022

Surf. Topogr.: Metrol. Prop.

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“…The empirical relationship (between surface roughness, cutting temperature and cutting speed, feed, depth of cut) has been validated by confirmation tests. Saini and Singh 26 studied the end milling of Al-4032/3%SiC MMC using a carbide cutter The occurrence of hard reinforcement in base Al-alloy makes the MMC difficult to machine. But machining turns relatively easier at high cutting speed and low feed rate, resulting in improved surface finish.…”

Section: Research Background and Motivationmentioning

confidence: 99%

Characterization and optimization analysis on surface finish and energy consumption in turning of Al-4032/GMP MMC produced by stir casting

Saini

Singh

2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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Control of energy expenditure in computer numerical control (CNC) machining is needed for eco-friendly operation of machining operations. Production industries deeply emphasize the improvement of productivity and saving in cost. The aluminum-based metal matrix composites (AMCs) can be substituted for metals for their mechanical properties in several applications. However, to bring in composite to usage, generally demand certain machining operation, which is quite challenging. This paper presents fabrication, characterization, and machining (turning) of Al-4032/6%GMP (granite marble powder) composite. Optical micrographs (OM) and scanning electron microscopy (SEM) with energy dispersive x-ray analysis (EDAX) have been used for the portrayal of the composite microstructure, surface topography, and fracture behavior. Also, mechanical characterization (tensile strength, micro-hardness, and impact strength) of the fabricated AMC has been carried out. The AMC samples have been examined for machinability for CNC turning operation. Cutting speed, feed rate, and depth of cut are the cutting parameters selected for the machining experiments. The response surface methodology (RSM)-based desirability function has been used to obtain the best combination of parameters for achieving the desired objectives. Experimental results demonstrate the built-up edge (BUE) formation on cutting insert and interfacial bonding of particles on workpiece surface at low cutting speed. Generally, smooth cutting operation has been observed at cutting speeds above 100 m/min. Best surface finish (1.38 μm) and minimum energy consumption (0.27 kWh) have been observed at cutting speed 176 m/min, feed rate 0.15 mm/rev, and depth of cut 0.45 mm.

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“…High cutting speed and low feed rate, however, make machining relatively simpler and increase surface smoothness. With a 0.066 feed rate (mm/ tooth), 157 cutting speed (m/min), and 0.528 depth of cut (mm), the best surface finish (Ra = 1.145 m) was accomplished [32]. An analysis of the evolution of the hybrid adaptive neuro-fuzzy inference system (ANFIS) model and the machinability of WEDM of stir-casted hybrid MMC (LM26+ Graphite+Fly ash) for predicting the desired variables.…”

Section: Introductionmentioning

confidence: 99%

Investigation on the machinability of Biochar reinforced AA5083 Metal Matrix composites fabricated by stir casting technique

Praveen,

Raja,

Jannet

et al. 2023

Eng. Res. Express

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Over the past two decades, there has been a significant rise in the demand for Aluminum Metal Matrix Composites (AAMCs) due to their notable advantages such as lightweight properties, increased strength, and enhanced hardness. In this study, three distinct AAMC samples based on Al5083 alloy, each varying in reinforcement levels at 4%, 8%, and 12% by weight were used. These composites were produced through a stir-casting process. The biochar used in our research was obtained through a pyrolysis process, adding an environmentally friendly and sustainable aspect to the composite materials. In the machining aspect of the study, A systematic L27 Taguchi Design of Experiment approach was used to investigate the influence of input parameters, namely cutting speed, feed rate, depth of cut, and weight percentage of reinforcement material, on the machining process. Further regression models were developed to gain insights into the relationships between these parameters and the resulting surface roughness. Turning operations at a cutting speed of 1050 rpm, a feed rate of 60 mm, and a depth of cut of 0.75 mm were idle for superior surface roughness and to assess the impact of the reinforcement material on the machined surface.

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Investigation on characterization and machinability of Al-4032/SiC metal matrix composite

Cited by 10 publications

References 32 publications

Effect of machining parameters on surface roughness and energy consumption during end milling of stir cast Al-4032/6%SiC composite

Effect of machining parameters on surface roughness and energy consumption during end milling of stir cast Al-4032/6%SiC composite

Characterization and optimization analysis on surface finish and energy consumption in turning of Al-4032/GMP MMC produced by stir casting

Investigation on the machinability of Biochar reinforced AA5083 Metal Matrix composites fabricated by stir casting technique

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