Surface Structure Analysis of Syntactic Metal Foams Machined by Milling

Abstract

IntroductionIn order to meet the market demands, the use of man-made composite materials is expected to grow tenfold in the future [1]. This forecast is confirmed by the expectations, awakened by the particularly favourable properties of composite materials, having different base materials. The primary objective of development of newer and newer metal matrix composites is to increase the mechanical strength, to make the friction and wear resistance more favourable, to influence the thermal expansion/stability, and the intention to reduce the mass while maintaining low density [4].The machining of composite materials requires new approach not only from the point of view of cutting tool geometry and tool material, but also from the aspects of interpretation of surface quality, machined by the tool (roughness, waviness, layer properties etc.); moreover, in the qualification of working surfaces of components, too. The matrices of metallic composites (Al, Cu etc.) are usually soft, while the reinforcement is created by abrasive materials, have great hardness (Al 2 O 3 , SiC etc). The last-mentioned materials wear out the traditional milling tools to a greater extent and the cutting temperature increases during the machining, too. From a surface point of view it means that the surface quality will be changed as a result of the significant mechanical impact, caused by the thermal dilatation, microstructural changes and cutting forces. Considering the roughness of the machined surface, it can be noticed that the extremely rapid wear of tool is determinant: parallel with the development of the wear process, there is a constant change in the roughness: it oscillates often, but seeing its tendency, mostly it becomes worse.

Investigating on the machinability assessment of precision machining pumice reinforced AA7075 syntactic foam

“…Szaloki et al. 40 measured surface roughness values of Al 2 O 3 reinforced Al6061 syntactic foams depending on milling operations. Kannan et al.…”

“…Pervaiz et al 39 analyzed the role of alumina micro balloons during machining of magnesium syntactic foams and claimed that there was an affirmative relation between filler volume fraction and machining forces. Szaloki et al 40 measured surface roughness values of Al 2 O 3 reinforced Al6061 syntactic foams depending on milling operations. Kannan et al 41 manufactured ceramic micro balloon added magnesium syntactic foams to explore their machinability.…”

An experimental examination of the dry drilling machinability features of cellular glass‐filled new‐generation metallic composite foams

“…A computer-controlled dynamometer was integrated into the cutting system to explore the influences of different cutting speeds and feed rates. The levels of the input parameters were determined by taking the some literature efforts into the consideration [24,27]. Drill diameter was kept constant as 8 mm.…”

Manufacturing and Investigation of In Situ and Ex Situ Produced Aluminum Matrix Foam‐Filled Tubes

“…In CMFs, the foam structure consists of hollow or porous particles used as fillers, such as ceramic hollow spheres (CHSs), [12] iron hollow spheres, [13] expanded perlite, [14] or lightweight expanded clay aggregate particles (LECAPs). [15] The alloys used as matrix material can vary widely due to different manufacturing processes (e.g., infiltration [16] and powder metallurgy [17] ), but are generally light metal alloys (mostly Al [18,19] and Mg [20,21] ) or alloys with good casting properties (Zn [22,23] and Fe [24,25] ).…”