Tool wear and surface quality of metal matrix composites due to machining: A review

Abstract

Higher tool wear and inferior surface quality of the specimens during machining restrict MMCs' application in many areas in spite of their excellent properties. The researches in this field are not well organised and knowledges are not properly linked to give a complete overview. Thus, it is hard to implement it in practical fields. To address this issue, this paper reviews tool wear and surface generation, and latest developments in machining of MMCs. This will provide an insight and scientific overview in this filed which will facilitate the implementation of the obtained knowledge in the practical fields. It was noted that the hard reinforcements initially start abrasive wear on the cutting tool. The abrasion exposes new cutting tool surface, which initiates adhesion of matrix material to the cutting tool and thus causes adhesion wear. Build-up-edges also generates at lower cutting speeds. Though different types of coating improve tool life, only diamond cutting tools show considerably longer tool life. The application of the coolants improves tool life reasonably at higher cutting speed. Pits, voids, micro-cracks, and fractured reinforcements are common in the machined MMC surface. These are due to ploughing, indentation, and dislodgement of particles from the matrix due to tool-particle interactions. Further, compressive residual stress is caused by the particles' indentation in the machined surface. At high feeds, the feed rate controls the surface roughness of the MMC, though, at low feeds, it was controlled by 2 particle fracture or pull-out. The coarser reinforced particles and lower volume fraction enhance microhardness variations beneath the machined surface.

A review on multi sensor data fusion technique in CNC machining of tailor-made nanocomposites

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Processing of duplex stainless steel by WEDM

“…The responses of materials under machining conditions comprehend the machinability of any material which also offers to understand about the important problems and emphasises main points needing fundamental attention [13][14][15]. Researchers applied WEDM process on different stainless steels such as, Huang et al, [16] investigated the EDM of tempered martensitic stainless steel at different WT, dielectric fluid pressure and power for semi-finish and finish cut.…”

Residual stress generation in metal matrix composites after cooling

“…Manufacturing operations such as heat treatment, surface hardening and welding induced residual stresses in the workpiece. For instance, machining operations, which are chip-removal processes (i.e., grinding and turning), lead to mechanically induced residual stresses in the material (8). Residual stresses that are thermally induced in the material due to heat treatment are also known as thermal residual stresses.…”