Effect of Feed Rate on Tool Wear in Milling of Al-4%Cu/B4CpComposite

Übeylı, Mustafa; Acır, Adem; Karakaş, Mustafa Serdar; Ögel, Bilgehan

doi:10.1080/10426910802385059

Cited by 19 publications

(12 citation statements)

References 23 publications

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“…In milling the composite, experimental results showed that flank wear of all of the investigated tools decreased as the feed rate increased at the same chip volume. 42 Tool wear showed an inverse relation to feed rate at the same cutting depth during the drilling process of metal-matrix composites. 43 Since exponent a /2 is small (approximately 0.3), the edge radius indicates no significant difference within the experimental range.…”

Section: Resultsmentioning

confidence: 97%

Modelling of thrust force for worn drill bits characterised by cutting edge radius in drilling carbon fibre–reinforced plastic/Ti-6Al-4V alloy stacks

Luo

Zhang

Yuan

et al. 2017

Proceedings of the Institution of Mechanical Engineers, Part B:

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Wear rates are rapid when drilling carbon fibre–reinforced plastics/Ti-6Al-4V alloy stacks because of their distinct mechanical properties. Tool wear leads to a high thrust force, thereby reducing the quality of the drilled holes. This article develops a novel mechanistic model for carbon fibre–reinforced plastics/Ti-6Al-4V stacks, which is characterised by the cutting edge radius, to predict the variation of the thrust force when drilling with worn drill bits. Drilling experiments with varying feed rates were performed using carbide twist drill bits. The thrust force and drill edge profile were measured to calibrate and validate the presented model. The edge radius increases with both the cutting distance and number of drilled holes at varying feed rates. It was found that the growth rate of the edge radius increased with the feed rate with identical cutting distances, whereas it decreased slightly with the feed rate when the number of drilled holes was identical. Tool wear reduces the equivalent rake angle of the drill edge, resulting in higher thrust force. The maximum thrust force increases almost linearly with the edge radius of worn drills for both materials. The predicted thrust force curves are in very good agreement with the measured curves during the entire process. Average absolute errors of the maximum thrust force for carbon fibre–reinforced plastics and Ti-6Al-4V alloy are 3.24% and 1.88%, respectively.

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Section: Resultsmentioning

confidence: 97%

Modelling of thrust force for worn drill bits characterised by cutting edge radius in drilling carbon fibre–reinforced plastic/Ti-6Al-4V alloy stacks

Luo

Zhang

Yuan

et al. 2017

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…For example, diamond blades cannot be used effectively when milling a composite reinforced with a 65% volumetric fraction of 10 μm SiC particles at a speed of above 300 m/min [26]. An interesting phenomenon was observed when machining an aluminium composite reinforced with short fibres and particles by means of tools made of respectively uncoated carbide and coated carbide [24]. Below the cutting speed of 250 m/min, cracks and spalls appeared, while above this speed the abrasive wear of the tool flank increased considerably.…”

Section: Introductionmentioning

confidence: 99%

Effectiveness of Diamond Blades in the Turning of Aluminium Composites

Karolczak¹,

Kołodziej²,

Kowalski³

2020

Adv. Sci. Technol. Res. J.

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Owing to their excellent strength-to-weight ratio aluminium composite materials are very readily used in the construction of means of transport. The parts made of such materials must be characterized by high reliability and workmanship. Hence, machining is the predominant method of manufacturing parts from composites. The problem with the turning, milling and drilling of ceramic-reinforced composites is the abrasive action of the reinforcement, resulting in heavy wear of the blades and so in lower surface quality and dimensional-shape accuracy and higher manufacturing costs. A solution to this problem can involve the blades made of superhard materials or properly matched conditions of machining with sintered carbide blades. This paper presents the results of the turning tests carried out on an aluminium composite material reinforced with long ceramic fibres. An uncoated sintered carbide blade is compared with a diamond coated blade and a polycrystalline diamond blade. Post-turning surface roughness and machining forces were selected as the main indicators of cutting ability. The effect of the blades on the forming chips is shown and the higher resistance of the polycrystalline diamond blades to the abrasive action of the reinforcing fibres is confirmed by microscopic photographs. Besides the confirmation of the higher durability of the diamond blades, the conditions in which when using these blades one can achieve better machining effects than the ones achievable by the compared tools are defined. Moreover, it is shown that by properly matching the machining parameters and aiding machining with oil mist lubrication, it is possible to obtain excellent surface quality by means of carbide blades. The minimum quantity lubrication also increases the life of the blades.

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“…Studies have shown that at higher feed rates, the rate of abrasive wear on the cutting tool decreases [93][94][95][96]. One of these studies attributes the decrease in wear to the thermal softening of the workpiece material as interface temperature rises [19].…”

Section: Effect Of Feed Ratementioning

confidence: 99%

Review of machining metal matrix composites

Nicholls

Boswell

Davies

et al. 2016

Int J Adv Manuf Technol

125

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Metal Matrix Composites (MMC) is a material which has been widely used in the aerospace and automobile industries since the 1980s, and has been classified as a hard to machine material. During the intervening years only a limited amount of research has been conducted into the cutting action of MMCs. As with traditional materials it is important to understand the wear mechanisms that contribute to tool wear reducing tool life. This review has been carried out to establish the optimum machining parameters vital to maximizing tool life whilst producing parts at the desired quantity and quality. The objective of this research is to evaluate the effectiveness of the machining parameters for these hard to machine material MMC.

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Effect of Feed Rate on Tool Wear in Milling of Al-4%Cu/B₄C_pComposite

Cited by 19 publications

References 23 publications

Modelling of thrust force for worn drill bits characterised by cutting edge radius in drilling carbon fibre–reinforced plastic/Ti-6Al-4V alloy stacks

Modelling of thrust force for worn drill bits characterised by cutting edge radius in drilling carbon fibre–reinforced plastic/Ti-6Al-4V alloy stacks

Effectiveness of Diamond Blades in the Turning of Aluminium Composites

Review of machining metal matrix composites

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