Study of cutting force and surface roughness in milling of Al/Sic metal matrix composites

Abstract

In this experimental study, composite samples containing silicon are produced with powder metallurgy technique by sintering under argon atmosphere. The effect of cutting speeds, feed rates and different cutting tool types on cutting forces and surface roughness are investigated in the face milling operation of silicon carbide particle reinforced aluminium metal matrix composites. Machining operations are conducted using coated and uncoated tools. Main cutting force (F x ) and surface roughness (Ra) are measured for at four different cutting speeds (300, 350, 400 and 450 m/min) and three different feed rates (0.1, 0.15, 0.20 mm/tooth) and two depth of cut (0.5, 1 mm). As a result of experimental evaluation for coated and uncoated tools, main cutting force increased with increasing feed rate and depth of cut whereas, it is decreased significantly by higher cutting speed. On the other hand, Al-SiC produces the worst surface finish with increasing feed rate and depth of cut in the uncoated tools whereas, the surface roughness in the coated tools are decreased under the same cutting conditions. The best surface roughness is obtained with increasing cutting speed for both uncoated and coated tools.Key words: Metal matrix composite, face milling, machining, cutting forces, surface roughness. INTRODUCIONRecently, the reinforced metal matrix composites (MMCs) are widely used in aerospace, automotive, electronic and medical industries. Silicon carbide (SiC) and alumina (Al 2 O 3 ) as the matrix phase in the production of metal matrix composites are used the popular reinforcement in the literature (Rohatgi, 1990;Monaghan, 1994;El-Gallab and Sklad, 1998;Koczak et al., 1993). Net shaping and good surface finish of particulate metal matrix composites (PMMCs) are very important for machining operations. However, PMMCs show poor machinability because of the fact that their reinforcements cause serious abrasive tool wear and the worst surface finish during machining

Cutting Forces and Surface Roughness in Face-Milling of SKD61 Hard Steel

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