Tool wear and chip formation analysis of aluminium hybrid metal matrix composite

Suthar, Jigar; Patel, Kaushik M.

doi:10.1016/j.matpr.2020.02.126

Cited by 8 publications

(6 citation statements)

References 20 publications

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“…It is well known from the literature that the main mechanisms affecting chip formation are considerably dependent on machining conditions, tool properties, and work-piece material. [72][73][74] In this study, the effects of machining parameters were focused on rather than the tool effects. Depending on different cutting speeds and feed rate values, micro images captured via SEM of collected matrix and pumice chips can be seen in Figure 10.…”

Section: Effects Of Machining Parameters On Chip Formationmentioning

confidence: 99%

Investigating on the machinability assessment of precision machining pumice reinforced AA7075 syntactic foam

Bolat

Ergene

Karakılınç

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part C:

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On the road to real applications, although there are lots of efforts focusing on mechanical and physical features in the literature, their machining abilities were examined in a very limited manner. In this study, machining properties of pumice reinforced AA7075 syntactic foams manufactured via the newly offered sandwich infiltration technique were investigated by performing face turning. Physical and microstructural (optical and SEM works) analyses were conducted on fabricated foams to carry out sample characterization. All machining forces were measured for different cutting speeds (25, 50, and 100 m/min) and feed rates (0.05, 0.10, and 0.15 mm/rev). After the turning operation, areal surface roughness values were measured using a 3D surface profilometer and material removal rate (MRR) values were calculated. Besides, chip mixtures including pumice and metal fragments were collected to probe chip morphology in detail. The results showed that machining forces were affected by the operation parameters differently, and the lowest surface roughness was detected at the cutting speed of 100 m/min and 0.05 mm/rev feed rate. Furthermore, the shape of the metal chips changed from long/continuous characteristic to saw-tooth morphology depending on increasing cutting speed levels while pumice particles exhibited breakaway tendency as the feed rates went up.

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Section: Effects Of Machining Parameters On Chip Formationmentioning

confidence: 99%

Investigating on the machinability assessment of precision machining pumice reinforced AA7075 syntactic foam

Bolat

Ergene

Karakılınç

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part C:

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show abstract

“…The high cutting velocity with a low feed rate resulted in the above chip condition. The formation of spring-type chips indicates a poor surface finish [18]. Sawtooth structures are absent in this chip.…”

Section: Chip Morphologymentioning

confidence: 93%

“…The study reported better surface finish, low tool wear, and reduced cutting forces with the rise in graphite content. Suthar et al [18] suggested that the combination of optimum cutting parameters and the type of reinforcement used would decide the surface finish of the aluminium hybrid composites under machining. Increased graphite content in the composite also reportedly led to low surface roughness.…”

Section: Introductionmentioning

confidence: 99%

Machinability Study on AA6061/2 SiC / Graphite Hybrid Nanocomposites Fabricated through Ultrasonic Assisted Stir Casting

Lagisetti

A.²,

Sukjamsri³

et al. 2022

Int. J. Automot. Mech. Eng.

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Aluminium-based hybrid metal matrix nanocomposites (AA-HMNCs) have numerous applications due to their higher strength-to-weight ratio and good mechanical and tribological properties. However, the machinability aspect of these materials must be carefully explored before employing them in various engineering applications. The present study involves the fabrication of AA6061/2 wt.% SiC/x wt.% graphite (x= 1, 2, 3) hybrid nanocomposites and subsequently subjecting them to machinability investigation. All the hybrid nanocomposite samples are fabricated through ultrasonic assisted stir casting technique. The effect of machining parameters and graphite content of the sample on cutting force and surface roughness is discussed based on experimental data. Experiments are performed based on the central composite design of response surface methodology, and the corresponding output responses are recorded. ANOVA analysis revealed that the graphite content has the highest authority over surface roughness and cutting force. High cutting speeds accompanied by low feed and depth of cut have resulted in reduced cutting forces and better surface finish. Chip morphology studies have also subsequently indicated better machinability with increased graphite content.

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“…To determine the characteristic forms of the chips obtained from each drilling process with various drilling parameters, the Zeiss Gemini model field emission scanning electron microscope was used. When the literature efforts are focused, chip formations are mostly dependent on the machining parameters, work-piece material, and tool properties [45][46][47]. In this experimental study, the effect of machining parameters was investigated meticulously, rather than material and tool properties.…”

Section: Chip Morphologymentioning

confidence: 99%

An experimental examination of the dry drilling machinability features of cellular glass‐filled new‐generation metallic composite foams

Bolat,

Ergene,

Akgun

et al. 2023

Materialwissenschaft Werkst

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On the way to the real industrial applications of the metal matrix composite foams, the machining issue is highly critical in terms of dimensional accuracy, surface quality, and design diversity. Therefore, especially for lightweight automotive and aerospace components, the drilling machinability properties of cellular glass‐added aluminum composite foams were examined in this paper, and this is the first initiative in the literature specific to millimeter‐scale glass and aluminum‐zinc matrix combination. To comprehend the drilling properties, the outputs of thrust force, cylindricity, material removal rate, specific cutting coefficient, circularity error, damage factor, surface roughness, and chip formation were measured elaboratively. The results showed that cylindricity and damage factor of foams elevated with the increased feed rates (from 0.05 mm×rev−1 to 0.2 mm×rev−1) and cutting speeds (from 25 m×min−1 to 100 m×min−1). Maximum thrust force value reached up to 150 N for 0.2 mm×rev−1 feed and 25 m×min−1 cutting speed. Besides, specific cutting coefficient values ranged between 360 MPa and 114 MPa. The highest surface roughness of 58.3 μm was obtained with the lowest cutting speed of 25 m×min−1, and the long/continuous chip structure converted into a separate/short structure based on rising feed and cutting speeds.

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Tool wear and chip formation analysis of aluminium hybrid metal matrix composite

Cited by 8 publications

References 20 publications

Investigating on the machinability assessment of precision machining pumice reinforced AA7075 syntactic foam

Investigating on the machinability assessment of precision machining pumice reinforced AA7075 syntactic foam

Machinability Study on AA6061/2 SiC / Graphite Hybrid Nanocomposites Fabricated through Ultrasonic Assisted Stir Casting

An experimental examination of the dry drilling machinability features of cellular glass‐filled new‐generation metallic composite foams

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