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The role played by hollow ceramic thin-walled aluminium oxide microballoons on the shear deformation characteristics of AZ31 Magnesium syntactic foam is studied through high-speed machining. The ceramic microballoons embedded in the AZ31 matrix provides the necessary stiffness for these novel foams. The effect of hollow ceramic microballoon properties, such as the volume fraction, thin wall thickness to diameter ratio, and microballoon diameter, profoundly affects the chip formation. A novel force model has been proposed to explain the causes of variation in cutting forces during chip formation. The results showed an increase in machining forces during cutting AZ31 foams dispersed with higher volume fraction and finer microballoons. At a lower (Davg/h) ratio, the mode of microballoon deformation was a combination of bubble burst and fracture through an effective load transfer mechanism with the plastic AZ31 Mg matrix. The developed force model explained the key role played by AZ31 matrix/alumina microballoon on tool surface friction and showed a better agreement with measured machining forces.

For machining of composites, Abrasive Water Jet Machining is widely employed. For assembly of the machine tool structure, production of slots is essential. In this paper, abrasive water jet machining of composite laminates was experimentally investigated for various cutting parameters in terms of average surface roughness (R a ) and kerf taper (K t ).By generating a response surface model, the experimental values obtained for quality characteristics (R a and K t ) were empirically related to cutting parameters. The effects of cutting parameters on quality characteristics were analyzed by utilizing empirical models and also optimized within the tested range based on desirability approach. The optimum parameter levels were also validated by confirmation test. From this investigation, it is evident that, for obtaining a minimum kerf taper, traverse speed, water pressure and abrasive mass flow rate are significant parameters and for obtaining less surface roughness traverse speed is the significant parameter.

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