Machinability Studies on Turning Al 6061alloy with 10% Reinforcement of B₄C on MMC

Abstract

Abstract. Aluminum Boron Carbide Metal Matrix Composites (Al-MMC) have revolutionized aeronautical and automobile industries, in the recent times due to their exceptional mechanical and physical properties. However it is seen that the machinability of these composites is greatly reduced by the hardness of constituent reinforcement particles. Moreover these constituent reinforcement particles serve as disadvantage by increasing tool wear accompanying undesirable depression in life of tool. This paper presents the experimental investigations on turning of Al6061 matrix metal reinforced with 10 % by weight of boron carbide (B4Cp) particles -which was fabricated using Stir casting method. Fabricated samples are turned on medium duty lathe of 2kW spindle power with Polycrystalline Diamond (PCD) inserts of 1500 grade at various cutting conditions by varying parameters. Hence, parameters such as power consumed by main spindle, machined surface roughness and tool wear are studied and recorded. Furthermore, study results are supported using concurring images obtained from Scanning Electron Microscopy (SEM). It is observed that surface finish and power consumed for 1500 grade insert are comparatively better at higher cutting speeds. Additionally it is observed that tool wear is strongly dependent on abrasive hard reinforcement particles.

Investigation of the Mechanical and Machinability Characteristics of Al6061 Composites Reinforced with B4C Particles

“…Different methods have been employed to assess the machinability property like the tool wear, cutting force measurement, surface finish etc. [10][11][12]14]. Power consumed during machining is one of the methods of assessing the machinability of the material.…”

“…The mesh size of 140 indicates the particle size distribution of the B 4 C powder, which is essential to ensure that the reinforcement material can be effectively dispersed and integrated into the matrix material. The characteristics of the reinforcement material play a critical role in determining the overall properties of the composite material[9,12].…”