A study surface integrity of aluminum hybrid composites during milling operation

Rasagopal, P.; Senthilkumar, P.; Nallakumarasamy, Gurusamy; Magibalan, Subramaniam

doi:10.1016/j.jmrt.2020.03.008

Cited by 19 publications

(6 citation statements)

References 18 publications

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“…The primary concerns in the dry milling of HMMCs are related to the increased feed and cutting speed , which result in elevated cutting temperatures. These high temperatures can make it challenging to achieve desirable surface roughness (measured as Ra) and maintain acceptable tool life [18]. The difficulty in maintaining acceptable tool life during dry milling of HMMCs is exacerbated by the presence of tough reinforcement particles, which pose a significant challenge in terms of controlling tool wear.…”

Section: Machining Of Hmmcsmentioning

confidence: 99%

Understanding the machining characteristics of Al6082 Hybrid metal matrix composites milled under cryogenic cooling conditions

Sivalingam,

Zhou,

Manickajothi

et al. 2023

Preprint

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Cutting fluid used in machining is under investigation nowadays to check the achievement of sustainability and the cleaner process by the machining process. Many attempts were made to find new cooling strategies as an alternative to the existing cooling methods. Cryogenic cooling was found to be an efficient cooling method to move towards sustainability for machining any kind of materials and to ensure green machining. Machining of Al6082 HMMC has been carried out under distinct cutting environments. The fallout of these cutting environments was studied based on the parameters like surface roughness, cutting temperature, chip morphology, and tool wear. The application of Cryogenic co2 substantially reduced the tool wear by 37% & 48% when compared to MQL and wet conditions. The sem image of the worn tool disclosed that the adoption of the cryogenic cooling technique lead to less crater wear and also prevented the peeling of the tool layer to some extent. The impressive cooling effect of cryogenic cooling also produced a good surface finish on the machined surface in comparison to the other cooling environments. Thus cryogenic cooling proved to be trustworthy in all the output parameters.

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Section: Machining Of Hmmcsmentioning

confidence: 99%

Understanding the machining characteristics of Al6082 Hybrid metal matrix composites milled under cryogenic cooling conditions

Sivalingam,

Zhou,

Manickajothi

et al. 2023

Preprint

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“…During milling SiCp/Al composites, feed rate, cutting speed, and depth of cut were demonstrated through experimental results as the most significant machining parameters for affecting surface roughness. 18 The feed rate/ uncut chip thickness influenced the cutting regimes including semi-brittle and ductile cutting, 19 thus affecting the machined surface morphology and superficial surface damage. Besides, the different material removal mechanisms of brittle ceramic particle and ductile Al matrix also influenced surface morphology.…”

Section: Introductionmentioning

confidence: 99%

Modeling and experimental study on tool-particle interaction and surface integrity in milling SiCp/Al metal matrix composites

Wang

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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High-efficient machining of SiC particles reinforced composites is always challenging mainly due to their poor surface integrity. In this study, a two-phase finite element model including the Al alloy matrix with Johnson-Cook model and SiC particle with elastic-brittle failure model were developed. The main purpose is to comprehensively investigate particle removal mechanisms and surface integrity following simulation and experimental studies on milling SiCp/Al composites. Specifically, the distributions of residual stress along the depth direction were predicted using finite element model. Results indicated that compressive residual stress mainly appeared on the machined surface, while tensile residual stress distributed at deeper depth down to 0.02 mm. Besides, different relative positions between tool and particle induced specific particle removal modes, which eventually led to various surface defects. Higher level of cutting speed (180 m/min) and feed rate (0.09 mm/tooth) aggravated surface defects and increased the thickness of broken-SiC layer in subsurface. The simulated machined surface defects and surface residual stress correlated well with the experimental observation, and the maximum error value of cutting force was less than 15%. The proposed finite element model was efficient to predict cutting force and distribution of residual stress along the depth direction.

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“…Machining lightweight materials (like Al alloy) is an important manufacturing process in the automobile and aerospace industries [1]. Moreover, the micro machining of Al alloy is gaining importance due to the increased applications in precision micro industries [2].…”

Section: Introductionmentioning

confidence: 99%

Influence of Feed Rate Response (FRR) on Chip Formation in Micro and Macro Machining of Al Alloy

Rahman

Bhuiyan

Sharma

et al. 2021

Metals

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In this paper, the investigation of chip formation of aluminum alloy in different machining strategies (i.e., micro and macro cutting) is performed to develop a holistic view of the chip formation phenomenon. The study of chip morphology is useful to understand the mechanics of surface generation in machining. Experiments were carried out to evaluate the feed rate response (FRR) in both ultra-precision micro and conventional macro machining processes. A comprehensive study was carried out to explore the material removal mechanics with both experimental findings and theoretical insights. The results of the variation of chip morphology showed the dependence on feed rate in orthogonal turning. The transformation of discontinuous to continuous chip production—a remarkable phenomenon in micro machining—has been identified for the conventional macro machining of Al alloy. This is validated by the surface crevice formation in the transition region. Variation of the surface morphology confirms the phenomenology (transformation mechanics) of chip formation.

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A study surface integrity of aluminum hybrid composites during milling operation

Cited by 19 publications

References 18 publications

Understanding the machining characteristics of Al6082 Hybrid metal matrix composites milled under cryogenic cooling conditions

Understanding the machining characteristics of Al6082 Hybrid metal matrix composites milled under cryogenic cooling conditions

Modeling and experimental study on tool-particle interaction and surface integrity in milling SiCp/Al metal matrix composites

Influence of Feed Rate Response (FRR) on Chip Formation in Micro and Macro Machining of Al Alloy

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