Investigations on the Machinability of Al/SiC/RHA Hybrid Metal Matrix Composites

Shoba, Chintada; Dora, Siva Prasad; Prathipati, Raju

doi:10.1007/s12633-019-0080-9

Cited by 15 publications

(5 citation statements)

References 26 publications

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“…Chintada et al, [6] taken Al356.2 as a base metal and added SiC (6%, 25 μm) and Rice Husk Ash (RHA) (6%, 35 μm) as reinforcements by stir casting method. The cylindrical rods of this composite were turned on lathe machine by taking input parameters as 'X' (40,60,100,150,200) m/min, 'Y' (0.14, 0.16, 0.2, 0.25) mm/rev, and 'Z' (0.5, 0.75, 1.0, 1.5, 2.0) mm.…”

Section: Methodology Used By Different Researchersmentioning

confidence: 99%

Characterization and Machinability Studies of Aluminium-based Hybrid Metal Matrix Composites – A Critical Review

Patil

Kore²,

Chinchanikar³

et al. 2023

ARFMTS

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Metal matrix composites (MMCs) are attracting automobile and aeronautical sector because of their superior mechanical and physical characteristics which ultimately reduce the weight of components and hence the energy requirements. These composites are prepared by adding various reinforcements into the base metal by the methods like stir casting, squeeze casting, stir and squeeze casting, sand casting, in-setu method, powder metallurgy etc. When more than one particle is added into the base metal; these composites are called as Hybrid Metal Matrix Composites (HMMCs). The machinability of these hard to cut materials is a challenging task in front of manufacturing industry. Present study considers turning operation of HMMC done on either lathe or CNC machine by using different cutting tool materials. This review focuses on effect of various cutting parameters like speed, depth of cut, feed and also the parameters like reinforcement particle type, particle size and weight percentage on the machinability issues like surface roughness, MRR, cutting forces, tool wear etc. Further the various optimization methods used to suggest the cutting parameters to obtain minimum surface roughness, minimum cutting forces, minimum tool wear and maximum Material Removal Rate (MRR) are addressed.

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Section: Methodology Used By Different Researchersmentioning

confidence: 99%

Characterization and Machinability Studies of Aluminium-based Hybrid Metal Matrix Composites – A Critical Review

Patil

Kore²,

Chinchanikar³

et al. 2023

ARFMTS

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“…In machining process while the cutting forces increments are seen because of increasing depth of cut which ultimately increases the cutting area of tool workpiece in cutting zone, which also improves the material removal process. Experiments have observed that in machining process of SiC particles higher amount of depth of cut in combined with increasing feed rate produces the more cutting forces as mentioned in [18,59] Furthermore it is seen in different experimental studies that the more amount of cutting speed at subsequently amount of reduced depth of cut in result cutting forces decreases. As the cutting forces are changes, resulting in broken chips and formed cutting edges.…”

Section: Comparison Of Experiments Values and Predicted Values Of Cutting Force For Sicp/al 45 And 50%mentioning

confidence: 96%

Modeling and optimization of cutting forces and effect of turning parameters on SiCp/Al 45% vs SiCp/Al 50% metal matrix composites: a comparative study

Laghari

2021

SN Appl. Sci.

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In this study, the proposed experimental and second-order model for the cutting forces were developed through several parameters, including cutting speed, feed rate, depth of cut, and two varying content of SiCp. Cutting force model was developed and optimized through RSM and compared for two different percentages of components SiCp/Al 45% and SiCp/Al 50%. ANOVA is used for Quantitative evaluation, the main effects plot along with the evaluation using different graphs and plots including residual analysis, contour plots, and desirability functions for cutting forces optimization. It provides the finding for choosing proper parameters for the machining process. The plots show that during increment with depth of cut in proportion with feed rate are able to cause increments in cutting forces. Higher cutting speed shows a positive response in both the weight percentage of SiCp by reducing the cutting force because of higher cutting speed increases. A very fractional increasing trend of cutting force was observed with increasing SiCp weight percentages. Both of the methods such as experiment and model-predicted results of SiCp/Al MMC materials were thoroughly evaluated for analyzing cutting forces of SiCp/Al 45%, and SiCp/Al 50%, as well as calculated the error percentages also found in an acceptable range with minimal error percentages. Article Highlights This study focuses on the effect of cutting parameters as well as different percentage of SiC particles on the cutting forces, while comparing the results of both SiC particles such as SiCp/Al 45%, and SiCp/Al 50% the result shows that there isn’t fractional amount of impact on the cutting force with nominal increasing percentages of SiC particles. Cutting speed in machining process of SiCp/Al shows positive response in reducing the cutting forces, however, increasing amount of depth of cut followed by increasing feed rate creates fluctuations in cutting force and thus increases the cutting force in the cutting process. The developed RSM mathematical model which is based on the box Behnken design show excellent competence for predicting and suggesting the machining parameters for both SiCp/Al 45%, and SiCp/Al 50% and the RSM mathematical model is feasible for optimization of the machining process with good agreement to experimental values.

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“…MRR and roughness values were found to be significantly affected by cutting speed and cutting force by feed rate. Chintada et al [21] found abrasion as the dominant factor causing flank tool wear while machining aluminium composites reinforced with SiC and rice husk ash particulates. Niu and Cheng [22] proposed that surface roughness in machining components can be reduced by decreasing depth of cut and increasing cutting velocity.…”

Section: Turning Studies On Aluminium Matrix Compositesmentioning

confidence: 99%

Turning of Aluminium Composites: Characteristics and Future Prospects

Gupta

Singh

2022

IOP Conf. Ser.: Mater. Sci. Eng.

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Aluminium matrix composites have widespread applications in different industrial areas including automobile and aerospace owing to their improved mechanical and tribological properties over conventional monolithic materials. As such, machining of these metal matrix composites is an important aspect to be studied in order to manufacture desired components with close tolerances. Presence of hard abrasive ceramic reinforcements in composites increases the chance of tool wear and hence, increased machining cost during conventional machining process. In order to improve machining characteristics of aluminium composites, machining is carried out using specialized carbide tools (both coated and uncoated), polycrystalline diamond inserts, CVD diamond coated inserts, etc. This paper presents a state-of-the-art review on turning of aluminium composites. Factors affecting machinability like content, size, and morphology of reinforcement along with matrix hardness are discussed. Effect of process variables such as cutting speed, feed rate, depth of cut, etc. on response variables such as tool wear, surface finish, cutting forces, cutting temperature, etc. has been highlighted. Moreover, failure mechanisms involved in turning process occurring due to debonding, plastic deformation, particle fracture, etc. are deliberated in this study. Various modelling and optimization studies in this area are discussed in detail as well. Furthermore, scope for future work in this area including sustainable machining is also elucidated.

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Investigations on the Machinability of Al/SiC/RHA Hybrid Metal Matrix Composites

Cited by 15 publications

References 26 publications

Characterization and Machinability Studies of Aluminium-based Hybrid Metal Matrix Composites – A Critical Review

Characterization and Machinability Studies of Aluminium-based Hybrid Metal Matrix Composites – A Critical Review

Modeling and optimization of cutting forces and effect of turning parameters on SiCp/Al 45% vs SiCp/Al 50% metal matrix composites: a comparative study

Turning of Aluminium Composites: Characteristics and Future Prospects

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