Tool wear acceleration in relation to workpiece reinforcement percentage in cutting of metal matrix composites

Li, Xiaoping; Seah, W.K.H.

doi:10.1016/s0043-1648(00)00524-x

Cited by 147 publications

(61 citation statements)

References 6 publications

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“…An increase in concentration of the SiC particles resulted in severe abrasive wear in the flank face of the tool. Similar observations are also reported by Xiaoping Li and Seah [31] and Fang et al [32] Xiaoping Li and Seah [31] and Fang et al [32] reported that, at this condition, the mechanism of wear in Al-SiC is abrasive and it is three-body abrasive wear. Further, they reported that the matrix at this condition is soft, and the SiC particles impacted by the tool cutting edge hit neighboring SiC particles and easily dislodge the particles.…”

Section: Microstructural Examination On the Chips And Tool Facessupporting

confidence: 88%

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Optimization of the Machinability of the Al-SiC Metal Matrix Composite Using the Dynamic Material Model

Mohan

Venugopal

Rajadurai

et al. 2008

Metall Mater Trans A

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The dynamic material model (DMM) method has been widely used for the macroscopic description of flow, fracture, and workability of materials under hot deformation. This investigation is aimed at proposing a new methodology for the optimization of hot machinability of a material using the DMM stability criteria. The constitutive flow behavior of Al-20 pct SiC has been evaluated in the temperature range 50°C to 350°C and the cutting velocity in the range from 25 and 300 m/min with the view to optimizing its machinability using the DMM instability parameters. The DMM instability parameters predicted a narrow region around 150°C and 150 m/min as the optimum domain for machining this material. It has been observed that the tool wear is minimum at optimal conditions. This investigation proved that the machinability could be optimized through the DMM.

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Section: Microstructural Examination On the Chips And Tool Facessupporting

confidence: 88%

“…At the same time, another part of the broken particle is carried into the chip by the matrix. [31] The fragments of the particles pushed by the tool edge are pressed in to the machined surface or fall out and are removed. The edge cuts the matrix again and the shear angle decreases.…”

Section: Microstructural Examination On the Chips And Tool Facesmentioning

confidence: 99%

Optimization of the Machinability of the Al-SiC Metal Matrix Composite Using the Dynamic Material Model

Mohan

Venugopal

Rajadurai

et al. 2008

Metall Mater Trans A

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“…Some researchers evaluated the mechanical properties (Rohatgi et al, 2002;Bienias et al, 2003;Zuoyong Dou et al, 2007), thermal properties , damping properties (Wu et al, 2006) and tribological properties (Surappa, 2008) with the use of fly ash as reinforcement in aluminum matrix composites (Senapati et al, 2015). However, these are difficult-to-machine materials due to the presence of very hard and brittle reinforcements, which also leads to their poor machinability involving high tool wear and surface imperfections (Li & Seah, 2001;Manna & Bhattacharyya, 2005). Sahoo et al (2013) presented the development of Al/SiCp (10%weight) metal matrix composite through a conventional casting process and studied its machinability characteristics in turning using multi-layer TiN coated carbide insert under dry environment based on Taguchi'sL9 orthogonal array.…”

Section: Introductionmentioning

confidence: 99%

Multi-regression prediction model for surface roughness and tool wear in turning novel aluminum alloy (LM6)/fly ash composite using response surface and central composite design methodology

Panda¹,

Senapati²,

Mishra³

2017

10.5267/j.ijiec

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Turning experiments were conducted on a novel aluminum alloy (LM6)/fly ash composite based on the response surface and face centered central composite design methodology. The effects of cutting parameters on surface roughness and tool wear were investigated. Multiple regression models were developed for the responses and the adequacies of the developed models were tested at 95% confidence interval using the analysis of variance (ANOVA) technique. Carbide inserts (Model: CNMG 120408-M5) were used for turning the specimens in a CNC turning machine (model: LT-16). The test for significance of the regression models, the test for significance on individual model coefficients and the lack-of-fit tests were performed using the statistical Design-Expert7.0v software environments. R2 indicated the model significance and the value was more than 97%, revealed that the relation between cutting responses and input parameters held good for more than 97% and the model was adequate.

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“…It was also found that in most cases, the tool wear was due to abrasion by the hard reinforcement particles in the matrix material (El-Gallab and Sklad, 1998a;Hung and Zhong, 1996;Davim, 2012;Luliano et al, 1998). Li and Seah (2001) found that the abrasive wear of the tool was accelerated when the percentage of the reinforcement in the MMC exceeded a critical value, which varies with the density and size of the reinforcement particles. Moreover, most of the studies about the machinability of MMC's were carried out using materials with ceramic particles with a size of 25 microns or larger, resulting in bad performance of the hard metal (WC) tools, (Durante et al, 1997;Muthukrishnan et al, 2008a;Muthukrishnan et al, 2008b).…”

Section: Introductionmentioning

confidence: 99%

Machinability of Al-SiC metal matrix composites using WC, PCD and MCD inserts

2014

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SUMMARY:The aim of this work is the study of the machinability of aluminium-silicon carbide Metal Matrix Composites (MMC) in turning operations. The cutting tools used were hard metal (WC) with and without coating, different grades and geometries of Poly-Crystalline Diamond (PCD) and Mono-Crystalline Diamond (MCD). The work piece material was AMC225xe, composed of aluminium-copper alloy AA 2124 and 25% wt of SiC, being the size of the SiC particles around 3 μm. Experiments were conducted at various cutting speeds and cutting parameters in facing finishing operations, measuring the surface roughness, cutting forces and tool wear. The worn surface of the cutting tool was examined by Scanning Electron Microscope (SEM). It was observed that the Built Up Edge (BUE) and stuck material is higher in the MCD tools than in the PCD tools. The BUE acts as a protective layer against abrasive wear of the tool. RESUMEN: Maquinabilidad de composites de matriz metálica Al-SiC usando herramientas de WC, PCD y MCD.El objetivo de este trabajo es el estudio de la maquinabilidad del material compuesto de matriz metálica aluminio-carburo de silicio en operaciones de torneado. Las herramientas de corte utilizadas han sido de metal duro con y sin recubrimiento, diferentes grados de diamante policristalino (PCD) y diamante monocristalino (MCD). El material mecanizado ha sido AMC225xe, compuesto de la aleación de aluminio AA 2124 con un 25% en peso de partículas de SiC con un tamaño medio de 3 μm. Los experimentos se han realizado con diferentes velocidades de corte en una operación de refrentado, midiendo la rugosidad superficial, las fuerzas y el desgaste de la herramienta. La superficie desgastada de la herramienta ha sido examinada en el microscopio electrónico (SEM). Se ha observado que el filo recrecido y el material adherido son mayores en el caso de las herramientas de MCD que en las de PCD. El filo recrecido actúa como una capa protectora contra la abrasión.

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Tool wear acceleration in relation to workpiece reinforcement percentage in cutting of metal matrix composites

Cited by 147 publications

References 6 publications

Optimization of the Machinability of the Al-SiC Metal Matrix Composite Using the Dynamic Material Model

Optimization of the Machinability of the Al-SiC Metal Matrix Composite Using the Dynamic Material Model

Multi-regression prediction model for surface roughness and tool wear in turning novel aluminum alloy (LM6)/fly ash composite using response surface and central composite design methodology

Machinability of Al-SiC metal matrix composites using WC, PCD and MCD inserts

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