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Experimental and Statistical Study on Machinability of the Composite Materials with Metal Matrix Al/B4C/Graphite

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Abstract

In this study, four types of Al/B4C/Graphite metal matrix composites (MMCs) were produced by means of a hot-pressing technique with reinforcement elements, B4C 8 wt pct and graphite (nickel coated) 0, 3, 5, and 7 wt pct. Machinability tests of MMC materials thus produced were conducted using four different cutting speeds (100, 140, 180, and 220 m/min), three different feed rates (0.1, 0.15, and 0.20 mm/rev), and a fixed cutting depth (0.5 mm), and the effects of the cutting parameters on the average surface roughness were examined. After the machinability tests, the height of the built-up edge (BUE) formed on the cutting tools related to the cutting speed and feed rate was measured. The test results were examined by designing a matrix according to the full factorial design and the average surface roughness, and the most important factors leading to formation of the BUE were analyzed by the analysis of variance (ANOVA). As a result of analysis, it was found that the lowest surface roughness value was with 7 wt pct graphite MMC material, while the highest was without graphite powder. Based on the statistical analysis results, it was observed that the most important factor affecting average surface roughness was the type of MMC material, the second most effective factor was the feed rate, and the least effective factor was the cutting speed. Furthermore, it was found that the most important factor affecting the formation of the BUE was the type of MMC material, the second most effective factor was the cutting speed, and the least effective factor was the feed rate.

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Acknowledgment

The authors sincerely thank the Karabük University Scientific Research Project Division for the financial support of Project No. KBÜ-BAP-13/2-DR-012.

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Authors and Affiliations

  1. Cumayeri Vocational School, Endustriel Molding, University of Düzce, Mehmet Akif Mah. Cumhuriyet Cad. No: 71/A, 81700, Cumayeri/Düzce, Turkey

    Engin Nas

  2. Faculty of Engineering, Machine Engineering, University of Karabük, Balıklarkayası Campus, 78050, Karabük, Turkey

    Hasan Gökkaya

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  1. Engin Nas
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  2. Hasan Gökkaya
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Correspondence to Engin Nas.

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Manuscript submitted December 26, 2016.

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Nas, E., Gökkaya, H. Experimental and Statistical Study on Machinability of the Composite Materials with Metal Matrix Al/B4C/Graphite. Metall Mater Trans A 48, 5059–5067 (2017). https://doi.org/10.1007/s11661-017-4237-0

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