Effect of the cutting condition and the reinforcement phase on the thermal load of the workpiece when dry turning aluminum metal matrix composites

Aurich, Jan C.; Zimmermann, Marco; Schindler, Stefan; Steinmann, Paul

doi:10.1007/s00170-015-7444-0

Cited by 24 publications

(10 citation statements)

References 29 publications

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“…A basic physical cutting model is employed to describe the chip formation mechanism. The thermal load acting on machining tool, cutting tool and workpiece in turning of Al/SiC MMCs was studied by Aurich et al [15]. They found that the Al MMCs undergo a higher thermal load than non-reinforced Al workpiece, as well as thermal load decreases when increase the feed rate or cutting speed.…”

Section: State-of-the-art Shaping Processes For Mmcs and Tool Wear Ismentioning

confidence: 99%

Micro-machinability of nanoparticle-reinforced Mg-based MMCs: an experimental investigation

Teng

Huo

Wong

et al. 2016

Int J Adv Manuf Technol

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As a composite material with combination of low weight and high engineering strength, metal matrix composites (MMCs) have been utilised in numerous applications such as aerospace, automobile, and bioengineering. However, MMCs are recognised as difficult-to-cut materials due to their improved strength and high hardness of the reinforcing particles. This paper presents an experimental investigation on micro-machinability of Mg-based MMCs reinforced with Ti and TiB 2 nano-sized particles. The tool wear of AlTiN-coated micro-end mills was investigated. Both abrasive and chip adhesion effect were observed on the main cutting edges, whilst the reinforcement materials and volume fraction play an important role in determining the wear type and severity. The influence of cutting parameters on the surface morphology and cutting force was studied. According to analysis of variance (ANOVA), depth of cut and spindle speed have significant effect on the surface roughness. The specific cutting energy, surface morphology and the minimum chip thickness was obtained and characterised with the aim of examining the size effect. Furthermore, higher cutting force and worse machined surface quality were obtained at the small feed per tooth ranging from 0.15 to 0.5 μm/tooth indicating a strong size effect. Overall, Mg/TiB 2 MMCs exhibit better machinability.

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Section: State-of-the-art Shaping Processes For Mmcs and Tool Wear Ismentioning

confidence: 99%

Micro-machinability of nanoparticle-reinforced Mg-based MMCs: an experimental investigation

Teng

Huo

Wong

et al. 2016

Int J Adv Manuf Technol

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“…Muthukrishnan and Davim [92] also supported that the feed rate has the highest statistical and physical influences on the SR, whereas Manna and Bhattacharayya [48] considered that the cutting speed, feed rate, and depth of cut had equal influences on the R a and R t values. Aurich et al [93] suggested that high cutting speeds and feed rates and moderate depths of cut needed to be used to decrease the thermal load of the workpiece. Muthukrishnan et al [35] found that the surface finish was superior at lower feed rates and higher cutting speeds for Fig.…”

Section: Surface Integrity and Machining Efficiencymentioning

confidence: 99%

A review on conventional and nonconventional machining of SiC particle-reinforced aluminium matrix composites

Chen

2020

Adv. Manuf.

103

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Among the various types of metal matrix composites, SiC particle-reinforced aluminum matrix composites (SiC p /Al) are finding increasing applications in many industrial fields such as aerospace, automotive, and electronics. However, SiC p /Al composites are considered as difficult-to-cut materials due to the hard ceramic reinforcement, which causes severe machinability degradation by increasing cutting tool wear, cutting force, etc. To improve the machinability of SiC p /Al composites, many techniques including conventional and nonconventional machining processes have been employed. The purpose of this study is to evaluate the machining performance of SiC p /Al composites using conventional machining, i.e., turning, milling, drilling, and grinding, and using nonconventional machining, namely electrical discharge machining (EDM), powder mixed EDM, wire EDM, electrochemical machining, and newly developed high-efficiency machining technologies, e.g., blasting erosion arc machining. This research not only presents an overview of the machining aspects of SiC p /Al composites using various processing technologies but also establishes optimization parameters as reference of industry applications.

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“…1,2 There have been numerous research and development on machining metal matrix composites by researchers and practitioners. 3–10 However, the surface roughness and form accuracy of the machined MMC components are often far from expectation due to the existence of micro particle reinforcement. 11,12 Furthermore, the decreased scales of cutting parameters in micro machining process enlarge the errors generated by the machine tools, cutting tools and the process variables.…”

Section: Introductionmentioning

confidence: 99%

“…The dynamic cutting models based on theoretical assumptions and experimental observations have also been developed or improved. 3–8,16,17 However, most of these models are developed from the conventional milling force model formulated from the tangential, radial and axial cutting forces as proposed by Altintas, 18 which can be given by where the chip thickness variation can be approximated as The corresponding cutting constants are given by where Øn is the shear angle and τs is the shear yield stress. Altintas also proposes a further understanding on the cutting mechanics particular for the development of cutting force model by incorporating the effect of tool edge radius in the micro reinforcement oriented micro cutting process onto the conventional force model.…”

Section: Introductionmentioning

confidence: 99%

Improved dynamic cutting force modelling in micro milling of metal matrix composites Part I: Theoretical model and simulations

Niu

Cheng

2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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Cutting force modelling for micro machining is of great importance for better understanding of the cutting mechanics in the process. As precision machining of metal matrix composites (MMCs) is much more complex than machining homogeneous materials, the accurate prediction of cutting force is critical to control the cutting performance and tooling life. This paper presents an improved theoretical dynamic cutting force model in MMCs micro milling process by using straight flute PCD end mills. The theoretical model is modified and improved based on the conventional milling force modelling while taking account of various factors including tooling geometries, the material microstructure, size effect and chip formation in the cutting process. An innovative expression on dynamic cutting force in micromachining MMCs is presented through the multiscale modelling and analysis. The cutting force coefficients are further defined through instantaneous cutting force signals analysis. Simulation results under varied cutting process variables are presented against a series of MMCs micro milling trials, which indicate that the improved dynamic cutting force model can predict the cutting force accurately and reveal more details on the cutting force variations in the process due to the material inhomogeneous nature. In addition, the optimal process variables can be readily explored through the dynamic force modelling and simulations so as to further improve the cutting performance.

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Effect of the cutting condition and the reinforcement phase on the thermal load of the workpiece when dry turning aluminum metal matrix composites

Cited by 24 publications

References 29 publications

Micro-machinability of nanoparticle-reinforced Mg-based MMCs: an experimental investigation

Micro-machinability of nanoparticle-reinforced Mg-based MMCs: an experimental investigation

A review on conventional and nonconventional machining of SiC particle-reinforced aluminium matrix composites

Improved dynamic cutting force modelling in micro milling of metal matrix composites Part I: Theoretical model and simulations

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