Experimental study of machinability in mill-grinding of SiCp/Al composites

Abstract

An attempt was made to investigate the machinability of SiCp/Al composites based on the experimental study using mill-grinding processing method. The experiments were carried out on a high-speed CNC machining center using integrated abrasive cutting tool. The effects of combined machining parameters, e g, cutting speed (v _s), feed rate (v _f), and depth of cut (a _p), with the same change of material removal rate (MRR) on the mill-grinding force and surface roughness (Ra) were investigated. The formation mechanism of typical machined surface defects was analyzed by SEM. The experimental results reveal that with the same change of material removal rate, lower mill-grinding force values can be gained by increasing depth of cut and feed rate simultaneously at higher cutting speed. With the same change of MRR value, lower surface roughness values can be gained by increasing the feed rate at higher cutting speed, rather than just increasing the depth of cut, or increasing the feed rate and depth of cut simultaneously. The machined surface of SiCp/Al composites reveals typical defects which can influence surface integrity.

Keywords

SiCp/Al composites / mill-grinding / machinability / mill-grinding force / surface roughness

References

[1] Zhou L, Huang ST, Wang D, . Finite Element and Experimental Studies of the Cutting Process of SiCp/Al Composites with PCD Tools [J]. Int. J. Adv. Manuf. Technol., 2011, 52: 619-626.

[2] Rawal S Metal-matrix Composites for Space Applications [J]. J. Min. Me.t Mat. S., 2001, 53: 14-17.

[3] Sahin Y, Kok M, Celik H Tool Wear and Surface Roughness of Al₂O₃ Particle-Reinforced Aluminium Alloy Composites [J]. J. Mater. Process. Technol., 2002, 128: 280-291.

[4] Allision JE, Gole GS Metal-Matrix Composites in the Automotive Industry: Opportunities and Challenges [J]. J. Min. Met. Mater Sci., 1993, 45: 19-24.

[5] Muller F, Monaghan J Non-Conventional Machining of Particle Reinforced Metal Matrix Composites [J]. J. Mater. Process. Technol., 2001, 118: 278-285.

[6] Ahamed AR, Asokan P, Aravindan S, . Drilling of Hybrid Al-5%SiCp-5%B4Cp Metal Matrix Composites [J]. Int. J. Adv. Manuf. Technol., 2010, 49: 871-877.

[7] Altunpak Y, Ay M, Aslan S Drilling of a Hybrid Al/SiC/Gr Metal Matrix Composites [J]. Int. J. Adv. Manuf. Technol., 2012, 60: 513-517.

[8] Pramanik A, Zhang LC, Arsecularatne JA Machining of Metal Matrix Composites: Effect of Ceramic Particles on Residual Stress, Surface Roughness and Chip Formation [J]. Int. J. Mach. Tools Manuf., 2008, 48: 1 613-1 625.

[9] Tosun G Statistical Analysis of Process Parameters in Drilling of AL/SICp Metal Matrix Composite [J]. Int. J. Adv. Manuf. Technol., 2011, 55: 477-485.

[10] Muthukrishnan N, Murugan M, Rao K P Machinability Issues in Turning of Al-SiC(10p) Metal Matrix Composites [J]. Int. J. Adv. Manuf. Technol., 2008, 39: 211-218.

[11] Kilickap E, Cakir O, Aksoy M, . Study of Tool Wear and Surface Roughness in Machining of Homogenised SiC-p Reinforced Aluminium Metal Matrix Composite [J]. J. Mater. Process. Technol., 2005, 164: 862-867.

[12] Ciftci I, Turker M, Seker U CBN Cutting Tool Wear during Machining of Particulate Reinforced MMCs [J]. Wear, 2004, 257: 1 041-1 046.

[13] Chou YK, Liu J CVD Diamond Tool Performance in Metal Matrix Composite Machining [J]. Surf. Coat Technol., 2005, 200: 1 872-1 878.

[14] Andrewes CJE, Feng HY, Lau WM Machining of an Aluminum-SiC Composite using Diamond Inserts [J]. J. Mater. Process. Technol., 2000, 102: 25-29.

[15] Manna A, Bhattacharayya B Influence of Machining Parameters on the Machinability of Particulate Reinforced Al/SiC-MMC [J]. Int. J. Adv. Manuf. Technol., 2005, 25: 850-856.

[16] Seeman M, Ganesan G, Karthikeyan R Study on Tool Wear and Surface Roughness in Machining of Particulate Aluminum Metal Matrix Composite-Response Surface Methodology Approach[J]. Int. J. Adv. Manuf. Technol., 2010, 48: 613-624.

[17] Bhushan RK, Kumar S, Das S Effect of Machining Parameters on Surface Roughness and Tool Wear for 7075 Al Alloy SiC Composite [J]. Int. J. Adv. Manuf. Technol., 2010, 50: 459-469.

[18] Kok M Modelling the Effect of Surface Roughness Factors in the Machining of 2024Al/Al₂O₃ Particle Composites Based on Orthogonal Arrays [J]. Int. J. Adv. Manuf. Technol., 2011, 55: 911-920.

[19] El-Gallab M, Sklad M Machining of Al/SiCp Metal Matrix Composites. Part I, Tool Performance [J]. J. Mater. Process. Technol., 1998, 83: 151-158.

[20] El-Gallab M, Sklad M Machining of Al/SiCp Metal Matrix Composites. Part II: Workpiece Surface Integrity [J]. J. Mater. Process. Technol., 1998, 83: 277-285.

[21] Huang ST, Zhou L, Yu XL, . Experimental Study of High-Speed Milling of SiCp/Al Composites with PCD Tools [J]. Int. J. Adv. Manuf. Technol., 2012, 62: 487-493.

[22] Reddy NSK, Kwang-Sup S, Yang MY Experimental Study of Surface Integrity during End Milling of Al/SiC Particulate Metal-Matrix Composites [J]. J. Mater. Process. Technol., 2008, 201: 574-579.