On tool–workpiece interactions during machining metal matrix composites: investigation of the effect of cutting speed

Ghandehariun, Amirmohammad; Kishawy, Hossam A.; Umer, Usama; Hussein, H.M.A.

doi:10.1007/s00170-015-7869-5

Cited by 35 publications

(12 citation statements)

References 18 publications

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“…The tool and the cutting speed were the parameters with more weight on the thrust force. The increase in the cutting speed caused a decrease in the thrust force due to the elevation of temperature, which softens the matrix, thus reducing its strength, as reported by [15]. In general, an increase in the feed rate leads to a higher thrust force associated with the elevation of the shear area, similar to the results reported by [3].…”

Section: Resultssupporting

confidence: 80%

Investigation on the Effect of Drill Geometry and Pilot Holes on Thrust Force and Burr Height When Drilling an Aluminium/PE Sandwich Material

et al. 2016

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Composite materials are widely employed in the naval, aerospace and transportation industries owing to the combination of being lightweight and having a high modulus of elasticity, strength and stiffness. Drilling is an operation generally used in composite materials to assemble the final product. Damages such as the burr at the drill entrance and exit, geometric deviations and delamination are typically found in composites subjected to drilling. Drills with special geometries and pilot holes are alternatives used to improve hole quality as well as to increase tool life. The present study is focused on the drilling of a sandwich composite material (two external aluminum plates bound to a polyethylene core). In order to minimize thrust force and burr height, the influence of drill geometry, the pilot hole and the cutting parameters was assessed. Thrust force and burr height values were collected and used to perform an analysis of variance. The results indicated that the tool and the cutting speed were the parameters with more weight on the thrust force and for burr height they were the tool and the interaction between tool and feed. The results indicated that drilling with a pilot hole of Ø4 mm exhibited the best performance with regard to thrust force but facilitated plastic deformation, thus leading to the elevation of burr height, while the lowest burr height was obtained using the Brad and Spur drill geometry.

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Section: Resultssupporting

confidence: 80%

Investigation on the Effect of Drill Geometry and Pilot Holes on Thrust Force and Burr Height When Drilling an Aluminium/PE Sandwich Material

et al. 2016

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“…According to previous studies on macro machining of micro-sized MMCs [13][14][15][16], addition of hard particles into matrix materials could greatly alter the cutting mechanism comparing with homogeneous materials. In fact, cutting tool edge radius is becoming one of the important factors governing the machining mechanism in micro machining process.…”

Section: Chip Formation Process Analysismentioning

confidence: 99%

“…Their research showed that the formation mechanism of machined surface defects was contributed by particles failure behaviours such as debonding, micro fracture, big cleavage and cutting through of particles. In order to obtain an in-depth understanding regarding the chip formation process and tool-particles interaction, Ghandehariun et al [15,16] developed a micromechanical FE model on machining Al/Al2O3 MMCs using cohesive zone element method. In their research, three main phases, namely matrix, particles, interface between matrix and particles were simulated separately.…”

Section: Introductionmentioning

confidence: 99%

Finite element modelling on cutting mechanism of nano Mg/SiC metal matrix composites considering cutting edge radius

Teng

Huo

Chen

et al. 2018

Journal of Manufacturing Processes

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Newcastle University ePrints -eprint.ncl.ac.uk Teng X, Huo D, Chen W, Wong E, Zheng L, Shyha I. Finite element modelling on cutting mechanism of nano Mg/SiC metal matrix composites considering cutting edge radius. AbstractIn the last two decades, metal matrix composites (MMCs) have been utilised in various industrial applications owing to their high strength-to-weight ratio and superior wear resistance. However, these superior mechanical properties bring poor machinability. The purpose of this paper is to perform a simulation study on the cutting mechanism of magnesium based MMCs reinforced with SiC nanoparticles. A two-dimensional micromechanical finite element (FE) model is established using ABAQUS/Explicit to simulate the micro machining process with consideration of cutting edge radius. The simulated results present tool-particles interaction, chip formation process, cutting force, Von Mises stress and strain distribution within workpiece under the effect of uncut chip thickness. The model is validated by comparing with experimental data in terms of cutting force and chip morphology.

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“…eir study recommends optimal process parameters such as pulse on time, pulse off time, spark gap voltage, peak current, wire tension, and wire feed rate for effective machining of Al/ SiCp-MMC. Ghandehariun et al [8,9] presented a micromechanical finite element analysis developed for simulation of MMC machining. e model can simulate the behavior of all main components that distinguish the MMC, namely, the matrix, particles, and particle-matrix interface during the process, so the debonding and fracture in the particles and different scenarios of tool-particle interactions can be studied using the proposed model.…”

Section: Introductionmentioning

confidence: 99%

Study on Grinding Mechanism of Brake Pad with Copper Matrix Composites for High-Speed Train

Sangwoo

Wang

Sun

et al. 2019

Advances in Materials Science and Engineering

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e processing mechanism of copper matrix composites is very complex, for the particle phase and lubricating phase are randomly distributed in the copper matrix phase, and the characteristics of the three phases are completely different. Aiming at understanding the chip formation and the influence of each phase of the material on the workpiece surface morphology, a single abrasive grain cutting experiment is carried out. Experiment results show that the cutting force increases with the increase in the cutting depth, but the increase amplitude is smaller. Extrusion of the abrasive particles causes plastic deformation of the copper matrix phase and brittle fracture of the particle phase and graphite phase. It results in the defects on the groove surface, such as pits, collapses and cracks, and holes. e brittle fracture of the graphite phase and the breaking and falling off of the particle phase block the plastic deformation of the copper alloy, which makes the copper alloy not forming ductile chips. e chip is mainly powdery. It shows that the brittle fracture is the main removal form of the brake pad material. e copper matrix phase on the surface of the groove produces obvious plastic deformation. e plastic deformation at the bottom is larger and has a certain degree of fibrosis appearing.

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On tool–workpiece interactions during machining metal matrix composites: investigation of the effect of cutting speed

Cited by 35 publications

References 18 publications

Investigation on the Effect of Drill Geometry and Pilot Holes on Thrust Force and Burr Height When Drilling an Aluminium/PE Sandwich Material

Investigation on the Effect of Drill Geometry and Pilot Holes on Thrust Force and Burr Height When Drilling an Aluminium/PE Sandwich Material

Finite element modelling on cutting mechanism of nano Mg/SiC metal matrix composites considering cutting edge radius

Study on Grinding Mechanism of Brake Pad with Copper Matrix Composites for High-Speed Train

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