Evaluation of Surface Integrity during Machining with Different Tool Grades of Sic_p/Al-Si Composites Produced by Powder Metallurgy

Abstract

MMCs components are mostly produced using near net shape manufacturing methods and are subsequently machined to the final dimensions and surface finishes. The MMCs consist of extremely hard reinforcing particles and pose considerable challenges due to the poor machinability and severe wear of the cutting tool. In this study, cutting performance of WC, CBN and PCD cutting tools were investigated with respect to surface roughness during machining of 10 wt % SiCp reinforced Al-Si alloy matrix composites produced by powder metallurgy (PM) method. Average surface roughness (Ra) corresponding to each machining condition was measured. After the machining process the worn insert tips were examined under the scanning electron microscope (SEM). Chip geometry and machined surface photographs have been taken by optical microscopy. The experimental results showed that surface roughness decreased with increasing cutting speed for all of cutting tool materials. The best surface integrity was occurred after the machining with PCD insert at the highest cutting speed employed.

Microstructure and mechanical properties of aluminium matrix boron carbide and carbon nanofiber reinforced hybrid composites

“…Ramesh et al, [22] reports that the friction coefficient decreases with increasing rate of carbon fibre reinforcement. In their study, Mindivan and Kayalı [20] reveal that the friction coefficients under 3 and 4.5 N test load vary between 0.5 and 1.…”

“…The TRS values of the samples decrease from 103 MPa to 53 MPa. Günay [20] explains that this decrease is associated with the pore/lubricant density causing a decrease in the density of composite material with increasing reinforcement rate. In order to determine the wear resistance of the Al-B 4 C/CNF composite, reciprocating wear test is performed in accordance with ASTM G133 standards under 5 N load at 200 m sliding distance and 0.06 m/s test speed.…”

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

“…Wang et al [98] conducted precision turning experiments to study the influence of particle size on the surface quality and proved that the SR (peak-valley value) was close to the particle radius. The performance of cutting tool materials has been evaluated in terms of surface quality from the best to the worst, which are PCD, CBN, and WC (for 10%(mass fraction) SiC p /Al) [99]. For example, while turning Al2124-SiC (45%(mass fraction)) MMCs, the PCD tool performed better than the CBN tool with lower flank wear and higher surface finish quality [100].…”

Thermomechanical Fatigue Behavior of Spray-Deposited SiCp/Al-Si Composite Applied in the High-Speed Railway Brake Disc

“…Several methods can be adopted to prepare the SiC p /Al-Si composites such as stir casting [9], powder metallurgy [10], and spray deposition [11]. Spray deposition is a rapid prototyping process to gas atomize a stream of molten metal by mean of high velocity gases (i.e., Ar or N 2 ) and to direct the resulting spray into a cold substrate [12].…”