Enhanced machinability of SiC-reinforced metal-matrix composite with hybrid turning

Bai, Wei; Roy, Anish; Sun, Ronglei

doi:10.1016/j.jmatprotec.2019.01.017

Cited by 94 publications

(23 citation statements)

References 18 publications

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“…In addition to outlined studies, different approaches have been tried for particle reinforced composite materials which need to be analyzing here considering key findings for clear understanding of their turning mechanisms. For example, Bai et al [31] investigated SiC P /Al composites using different cutting tools and cooling conditions while turning in order to research tool wear and surface roughness. Shoba et al [32] showed that increasing SiC reinforcement gradually decreases the cutting force components due to the dislocation density between reinforcement and matrix materials.…”

Section: Introductionmentioning

confidence: 99%

Parametric Optimization for Improving the Machining Process of Cu/Mo-SiCP Composites Produced by Powder Metallurgy

et al. 2021

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The features of composite materials such as production flexibility, lightness, and excellent strength put them in the class of materials that attract attention in various critical areas, i.e., aerospace, defense, automotive, and shipbuilding. However, the machining of composite materials displays challenges due to the difficulty in obtaining structural integrity. In this study, Cu/Mo-SiCP composite materials were produced by powder metallurgy with varied reinforcement ratios and then their machinability was investigated. In machinability experiments, the process parameters were selected as cutting speed (vC), feed rate (f), depth of cut (aP), and reinforcement ratio (RR). Two levels of these parameters were taken as per the Taguchi’s L8 orthogonal array, and response surface methodology (RSM) is employed for parametric optimization. As a result, the outcomes demonstrated that RR = 5%, f = 0.25 mm/rev, aP = 0.25 mm, vC = 200 m/min for surface roughness, RR = 0%, f = 0.25 mm/rev and aP = 0.25 mm and vC = 200 m/min for flank wear and RR = 0%, f = 0.25 mm/rev, aP = 0.25 mm, vC = 150 m/min for cutting temperature for cutting temperature and flank wear should be selected for the desired results. In addition, ANOVA results indicate that reinforcement ratio is the dominant factor on all response parameters. Microscope images showed that the prominent failure modes on the cutting tool are flank wear, built up edge, and crater wear depending on reinforcement ratio.

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Section: Introductionmentioning

confidence: 99%

Parametric Optimization for Improving the Machining Process of Cu/Mo-SiCP Composites Produced by Powder Metallurgy

et al. 2021

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“…Muhammad et al [16,17] developed a hot ultrasonically assisted turning (HUAT) set-up for aged Ti 15333 alloy, and an enhanced reduction in the cutting force was observed. Bai et al [18] observed a reduction of around 44.3% in average surface roughness (R a ) with WC tool in case of UAT as compared with CT of metal-matrix composite. Furthermore, Feyzi et al [19] concluded that there was a 7-14% reduction in cutting force and a 9-14% reduction in flank wear in hybrid (CT + UAT) machining.…”

Section: Introductionmentioning

confidence: 99%

Comprehensive experimental analysis and sustainability assessment of machining Nimonic 90 using ultrasonic-assisted turning facility

Airao

Khanna

Roy

et al. 2020

Int J Adv Manuf Technol

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Many techniques have been developed to improve the machinability of aeronautical materials titanium and nickel-based alloys such as ultrasonic-assisted turning, laser-assisted turning, and cryogenic-assisted turning. This collaborative scientific investigation presents the steps taken to gain insight into the phenomena of machining Nimonic 90 (a nickel-based alloy) alloy using ultrasonically assisted turning. The cutting speed, feed rate, depth of cut, and frequency are taken as input parameters and average surface roughness (R a ), power consumption (P), and chip formation are considered as output parameters. The experiments are carried out with the full factorial design. The UAT (ultrasonically assisted turning) process gives a significant improvement in average surface roughness and power consumption because of the intermittent cutting action of the cutting tool. UAT process shows a 70-80% reduction in average surface roughness (R a ) and a 6-15% reduction in power consumption as compared with CT (conventional turning) process. Ultrasonically assisted turning also resulted in the thin and smoother chips as compared with CT process which helps to achieve a more superior machining effect. Finite element modeling shows that the quasi-static nature of the stress induced in the UAT process leads to lower force and ultimately lower power generation. Moreover, a sustainability assessment model is implemented to investigate the effect of UAT in terms of machining performance as well as sustainability effectiveness in a single integrated approach. The novelty of this work lies in providing an integrated concept that combines experimental analysis and sustainability assessment when using ultrasonic vibrational energy during turning of Nimonic 90.

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“…The hard reinforcing particles were responsible for the reported decrease in ductility of the AA 6082 base metal [23,24]. The reduction in the ductility ultimately led to the brittleness of the workpiece thereby resulting in the production of the discontinuous chips as well as the serrated chip observed for all the experimental runs [25]. The tool-chip friction and increased feed and depth of cut are also responsible for the formation of the discontinuous chips [26].…”

Section: Chip Morphologymentioning

confidence: 99%

Machinability Studies and Optimization of AA 6082/Fly Ash/Carbonized Eggshell Matrix Composite

Ononiwu¹,

Ozoegwu²,

Madushele³

et al. 2021

RCMA

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Machinability studies of aluminium matrix composites (AMCs) is a necessary investigation required to understand their behaviour during machining to produce components effectively and efficiently. This established need has led to the investigation into the machinability of AA 6082 reinforced with 2.5 wt.% fly ash and 2.5 wt.% carbonized eggshell fabricated via stir casting. The studied machinability indices were material removal rate (MRR), cutting temperature, built-up edges (BUE) formation and chip morphology while the selected inputs were cutting speed (100 mm/min, 200 mm/min, 300 mm/min), feed (0.1 mm/rev, 0.2 mm/rev, 0.3 mm/rev) and depth of cut (0.5 mm, 1 mm, 1.5 mm). For the experimental design, the L9 orthogonal array was preferred to create 9 experimental runs. The analysis of the built-up edges showed that it increased at lower cutting speeds and increased feed and depth of cut. The examination of the produced chips after each experimental run showed the presence of c-shaped, helically shaped and ribbon-shaped chips. The analysis of variance (ANOVA) for both MRR and cutting temperature indicated that the depth of cut was the most influential factor on both responses. Multi-objective optimization using desirability function analysis showed that the optimum combination of parameters was 300 mm/min, 0.2 mm/rev and 1.0 mm for the cutting speed, feed and depth of cut respectively. The ANOVA of the composite desirability indicated that the cutting speed was the most contributing factor.

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Enhanced machinability of SiC-reinforced metal-matrix composite with hybrid turning

Cited by 94 publications

References 18 publications

Parametric Optimization for Improving the Machining Process of Cu/Mo-SiCP Composites Produced by Powder Metallurgy

Parametric Optimization for Improving the Machining Process of Cu/Mo-SiCP Composites Produced by Powder Metallurgy

Comprehensive experimental analysis and sustainability assessment of machining Nimonic 90 using ultrasonic-assisted turning facility

Machinability Studies and Optimization of AA 6082/Fly Ash/Carbonized Eggshell Matrix Composite

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