Study on Machining Parameters for Thrust Force and Torque in Milling AA7039 Composites Reinforced with Al2O3/B4C/SiC Particles

Abstract

Abstract-Metal matrix composites are used in many industrial fields such as automobile, military and aerospace applications due to their superior mechanical properties. In the present study, three aluminum 7039 metal matrix composite (MMCs) samples reinforced with 10 wt.% particulates of aluminum oxide (Al 2 O 3 ), 10 wt.% boron carbide (B 4 C), and 10 wt.% silicon carbide (SiC) were successfully fabricated using a powder metallurgy and hot extrusion method. The influences of cutting parameters on the thrust cutting force and torque during milling of the three MMCs were investigated under dry machining conditions. The milling tests were performed based on the Taguchi orthogonal -array design of experiments, for different machining parameters such as cutting speed, feed and depth of cut. The effect of reinforcement contents on cutting force and torque were specified by utilizing analysis of variance (ANOVA). Mathematical models have been generated for the thrust force and torque through regression method. The results indicated that the minimal thrust force and torque were obtained in the machining of the Al 2 O 3 reinforced specimen. The cutting force was directly influenced by the cutting feed and the axial cutting depth was the most effective machining parameter affecting milling torque in the machining of three composite specimens. The experimental results were modeled using regression analysis and artificial neural networks (ANN) to predict the thrust force and torque. The thrust force and torque were predicted with a mean squared error equal to 5.85% and 5.12% respectively using ANN models.

Feasibility of tool configuration and the effect of tool material, and tool geometry in multi-hole simultaneous drilling of Al2024

“…The spindle speed did not show any significant impact on the thrust force; however, as the spindle speed increased only a slight decrease or at high feeds, a slight increase was observed. The slight decreased in the thrust force due to an increase in spindle speed was due to an increase in the cutting temperature which affected the strength of the workpiece in the plastic deformation region and thus, cutting forces decreased [40]. According to Zhang et al [41], during the drilling process, most of the heat in the plastic deformation zone and the surrounding regions at the interfaces between the tool, workpiece and chip caused the high temperature.…”

Performance Analysis of Multi-Spindle Drilling of Al2024 with TiN and TiCN Coated Drills Using Experimental and Artificial Neural Networks Technique

“…2020, 10, x FOR PEER REVIEW 5 of 20 spindle speed. According to Karabulut [41], the increase in temperature at high spindle speed affects the strength of the workpiece and causes the plastic deformation of the workpiece, which leads to a reduction in thrust force. Further, at the highest spindle speed selected in this study, a slight increase in the thrust force was observed at the high feed, which might be due to the increase in the number of holes, which promotes tool wear due to high friction at the interface of the tool-workpiece and subsequent high-force generation [42].…”

Deform 3D Simulation and Experimental Study in Machining of AISI 1020 Mild Steel

“…Tis reduction can be attributed to the heat generated in the penetration area of the drilled hole, which lowers the material's hardness and, hence, results in a lower Fz [48]. Additionally, the Fz decreases due to increased material ductility caused by n drilling temperature [49,50]. Figure 7 demonstrates that a rise in f from 0.12 to 0.3 mm/rev leads to rise in Fz.…”