Tool Wear in Machining AlSi/AlN Metal Matrix Composite 10 Wt% Reinforcement Using Uncoated Cutting Tool

Abstract

Aluminum silicon (Al/Si) alloy, a metal matrix composite (MMC), is widely used in various industrial sectors, such as transportation, domestic equipment, aerospace, military, and construction. Al/Si alloy is a matrix composite reinforced with aluminum nitride (AlN) particle and transformed into a new-generation material for automotive and aerospace applications. AlN material is an advanced material characterized by light weight, high strength, and high hardness and stiffness, which makes it suitable for various future applications. However, its high ceramic particle reinforcement and the irregular nature of these particles along the matrix material make it a low density material. This low density is the main cause of problems during machining of this material. This paper studies tool wear in milling AlSi/AlN metal matrix composite by using an uncoated carbide cutting tool. The volume of AlN reinforced particle was 10%. The milling process was carried out under dry cutting conditions. The uncoated carbide insert parameters used were the following: cutting speed of 230 m/min to 370 m/min, feed rate of 0.4, 0.6, and 0.8 mm/tooth, and a corresponding depth of cut (DOC) of 0.3, 0.4, and 0.5 mm, respectively. Sometech SV-35 video microscope system was used for tool wear measurements. Results revealed that tool wear increases at 230 m/min cutting speed, 0.4 mm/tooth feed rate, and 0.3 mm depth of cut. The medium cutting speed, specifically the 300 m/min cutting speed, 0.4 mm/tooth feed rate, and 0.5 mm DOC, is the optimum condition for a longer tool life (82.94 min) and is ideal for cutting AlSi/AlN MMCs.

Milling Al520-MMC Reinforced with SiC Particles and Additive Elements Bi and Sn

“…It was stated that the optimum surface quality occurs at the lowest level of depth of cut. This underlines that depth of cut has a significant effect on cutting force [11,15]. In addition, limited studies have been reported on the effects of various reinforcing elements on the machinability of Al-MMC, in principle flank wear morphology and size.…”

“…Many studies have reported the machining of superalloys and MMCs using ceramic tools [12,14]. According to literature, the initial wear of carbide tools at intermediate to high cutting speeds has not been studied in a broad scope [11,15]. Most of the reported research studies on the machinability of aluminum substrate composite have revealed the significant effects of depth of cut and feed rate.…”