Evaluation of the Surface Integrity when Machining LM6 Aluminum Metal Matrix Composites Using Coated and Uncoated Carbide Cutting Tools

Hadzley, Abu Bakar Mohd; Sarah, Ahmad Siti; Izamshah, R.; Mohd, Amran Ali; Kasim, Mohd Shahir; Sulaiman, Mohd Amri; Fatin, Mohamad Raffi Nurul

doi:10.4028/www.scientific.net/amm.465-466.1049

Cited by 6 publications

(5 citation statements)

References 5 publications

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“…Another possible mechanism was the presence of a built-up edge that altered the nose radius of the cutting tool. A built-up edge is the formation of molten metal that adheres to the nose radius due to high temperatures generated at the tool-chip interface [6]. The existence of a built-up edge may indicate that the coolant did not penetrate the cutting zone due to the higher cutting speed or feed rate that splashing away the coolant.…”

Section: Methodsmentioning

confidence: 99%

Study on Surface Integrity of AISI 1045 Carbon Steel when machined by Carbide Cutting Tool under wet conditions

et al. 2017

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Abstract. This paper presents the evaluation of surface roughness and roughness profiles when machining carbon steel under wet conditions with low and high cutting speeds. The workpiece materials and cutting tools selected in this research were AISI 1045 carbon steel and canela carbide inserts graded PM25, respectively. The cutting tools undergo machining tests by CNC turning operations and their performances were evaluated by their surface roughness value and observation of the surface roughness profile. The machining tests were held at varied cutting speeds of 35 to 53 m/min, feed rate of 0.15 to 0.50 mm/rev and a constant depth of cut of 1 mm. From the analysis, it was found that surface roughness increased as the feed rate increased. Varian of surface roughness was suspected due to interaction between cutting speeds and feed rates as well as nose radius conditions; whether from tool wear or the formation of a built-up edge. This study helps us understand the effect of cutting speed and feed rate on surface integrity, when machining AISI 1045 carbon steel using carbide cutting tools, under wet cutting conditions.

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Section: Methodsmentioning

confidence: 99%

Study on Surface Integrity of AISI 1045 Carbon Steel when machined by Carbide Cutting Tool under wet conditions

et al. 2017

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“…Quality is one of the important aspects in drilling industries. Surface roughness and hole appearance are among the important indicator that related to quality in machining processes [4][5].…”

Section: 10 Introductionmentioning

confidence: 99%

Surface Roughness Optimization in Drilling Process Using Response Surface Method (RSM)

et al. 2014

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This paper presents the effect of drilling parameters on surface roughness and surface appearance by applying response surface method (RSM). The mathematical model for correlating the interactions of drilling parameters such as spindle speed, feed rate and drill diameter on surface roughness was developed. RSM methodology was used as it is a technique that most practical and effective way to develop a mathematical model. In addition, this method also can reduce trial and error in experiment. Since the number of factors are three; spindle speed, feed rate and drill diameter, by applying RSM the total numbers of experiment involved are 20 experimental observations. From the experimental result, it is found that the minimum surface roughness on the hole was 1.06 mm from combination of 2000 rpm spindle speed, 78 mm/min feed rate and 2.5 mm drill diameter. While the maximum surface roughness 2.59 mm was the combination of 250 rpm spindle speed, 153 mm/min feed rate and 3.5 mm drill diameter. A mathematical equation was developed with percentage of error are 0% to 29%. Thus, from the result we understand that to find the smooth surface in drilling process, it needs higher spindle speed with lower feed rate and smaller diameter.

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“…Usually in die tooling, when materials used is hard, it becomes better for die tooling, however it would be difficult to cutting using conventional cutting tools [3]. Therefore, some others electrode materials were tested against the aluminium alloys LM6 like copper tungsten [4], copper [5] and graphite [6] which has yielded a good experimental result.…”

Section: Introductionmentioning

confidence: 99%

“…It is widely used in many fabrication devices due to its characteristics properties such as applications for motor housings, manifolds, marine components and pumping cases. Further, LM6 is also appropriate where sometimes castings require to be welded.Usually in die tooling, when materials used is hard, it becomes better for die tooling, however it would be difficult to cutting using conventional cutting tools [3]. Therefore, some others electrode materials were tested against the aluminium alloys LM6 like copper tungsten [4], copper [5] and graphite [6] which has yielded a good experimental result.…”

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confidence: 99%

The Performance of Brass Electrode on Material Removal for Aluminium Composite in EDM Die-Sinking

Mohd

Laily

Fatin

et al. 2014

AMM

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Abstract. This paper investigates the performance of brass electrode on the removal of aluminium alloys LM6 (Al-Sil2) in an electrical discharge machining (EDM) die-sinking. The machining parameters such as pulse-on time, pulse-off time and peak current were selected to find the responses on the material characteristics such as material removal rate (MRR), electrode wear rate (EWR) and surface roughness (Ra). Brass with diameter of 10mm was chosen as an electrode. Orthogonal array of Taguchi method was used to develop experimental matrix and to optimize the MRR, EWR and Ra. It is found that the current is the most significantly affected the MRR, EWR and Ra while pulse on time, pulse off time and voltage are less significant factor that affected the responses. Percentage optimum value of MRR increases to 3.99%, however EWR and Ra reduce to 3.10% and 2.48% respectively. Thus, it shows that brass having capability to cut aluminium alloys LM6. IntroductionBrass is one of the electrical conductive materials. Today, however, brass is seldom used as an electrode in EDM die sinking due to its high wear rate but it still good for machining materials for high speed small hole machines because it exhibits higher degree of stiffness and easier to machine than copper [1]. Even though, brass already used as an electrode but it is still not tested for cutting aluminium alloys LM6. It is known that LM6 which aluminium containing 12% silicon has good resistance to corrosion and excellent cast ability [2]. It is widely used in many fabrication devices due to its characteristics properties such as applications for motor housings, manifolds, marine components and pumping cases. Further, LM6 is also appropriate where sometimes castings require to be welded.Usually in die tooling, when materials used is hard, it becomes better for die tooling, however it would be difficult to cutting using conventional cutting tools [3]. Therefore, some others electrode materials were tested against the aluminium alloys LM6 like copper tungsten [4], copper [5] and graphite [6] which has yielded a good experimental result. A special advantage of EDM die-sinking offers compared to conventional machine where materials removed without any contact between electrode and workpiece. As a result, problems of vibration and mechanical stress can be eliminated during machining process [7].Even though, the use of die-sinking EDM focused on the cutting material having conductivity of an electric, the process capability of cutting alloys materials, becomes more challenges regardless of their hardness and toughness [8]. The most advantage of EDM die-sinking machine is that it can cut electrical conductivity material, free from burrs especially for stamping die that can be produced by EDM die-sinking with accurate dimension, low cost and fast processes [9].

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Evaluation of the Surface Integrity when Machining LM6 Aluminum Metal Matrix Composites Using Coated and Uncoated Carbide Cutting Tools

Cited by 6 publications

References 5 publications

Study on Surface Integrity of AISI 1045 Carbon Steel when machined by Carbide Cutting Tool under wet conditions

Study on Surface Integrity of AISI 1045 Carbon Steel when machined by Carbide Cutting Tool under wet conditions

Surface Roughness Optimization in Drilling Process Using Response Surface Method (RSM)

The Performance of Brass Electrode on Material Removal for Aluminium Composite in EDM Die-Sinking

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