Tool Wear in Turning of Graphitic Hybrid Metal Matrix Composites

Abstract

This study presents an experimental investigation on tool wear in machining Al 2219/15SiCp and Al 2219/15SiCp-3Gr (hybrid) composites at different cutting conditions with carbide, coated carbide, and polycrystalline diamond (PCD) tools. An attempt is made in the present investigation to study the effect of graphite incorporation in Al 2219/15SiCp composite on tool wear. The results reveal that the incorporation of graphite in Al 2219/15SiCp composite reduces tool wear at all cutting conditions. This is due to graphite, which reduces the coefficient of friction between tool and workpiece and between tool and chip interface. PCD tool performs better than carbide and coated carbide tools.

Influence of graphite particles on surface roughness and chip formation studies in turning metal matrix composites

“…It is the second hardest material after diamond with a Mohr's hardness of 9.5. The graphite particles used for hybrid composites are of 45 mm size and average density of 2.25 g/cm 3 . The composites were fabricated by using liquid metallurgy technique.…”

“…The metal matrix selected for present investigation was based on Al-Cu-Mg alloy system, designated by the American Aluminium Association as AA 2219. The SiC particles, which were used to fabricate the composite, had an average particle size of 23 mm and average density of 3.2 g/cm 3 . It is the second hardest material after diamond with a Mohr's hardness of 9.5.…”

“…Although these composites have excellent performance characteristics, their poor machining efficiency leads to severe cutting tool wear, and difficulty in obtaining the fine surface quality was explained in review by Basavarajappa et al 1 . Pramanik et al 2 , Basavarajappa 3 and Chou and Liu 4 were reported that the main concern when machining of particulate metal matrix composites is extremely high tool wear and poor surface finish due to the abrasive action of the ceramic reinforcing particles compared to monolithic alloys. This is due to the presence of hard ceramic particles in composites, which acts as small cutting edges resulting in poor surface finish.…”

Study of Nano-Mechanical, Electrochemical and Raman Spectroscopic Behavior of Al6061-SiC-Graphite Hybrid Surface Composite Fabricated through Friction Stir Processing

“…as they exhibit high strength, wear resistance, abrasion resistance, chemical stability, and dimensional stability at high temperature [1,2]. Friction stir processing (FSP) is a solid-state processing strategy used for the fabrication of surface composites.…”

Enhancing the machinability of hypereutectic Al-30Si alloy by friction stir processing

“…Particulate composite materials are known for having poor machinability due to the high tool wear and poor surface finish arising from the abrasive hard particles, which act as small cutting surface thus resulting in poor surface finish [6][7][8][9][10][11]. Farid et al [12] reported the effect of feed rate and cutting speed on chip morphology of hypereutectic A383 (Al-11.5 Si) alloy by high speed drilling operation.…”