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Applied Composite Materials

, Volume 1, Issue 6, pp 431–447 | Cite as

Single-point scratching of 6061 Al alloy reinforced by different ceramic particles

  • Cheng Yan
  • Liangchi Zhang
Article

Abstract

Aluminium alloys reinforced by ceramic particles have been widely used in aerospace and automotive industries for their high stiffness and wear resistance. However, the machining of such materials is difficult and would usually cause excessive tool wear. The effect of ceramic particles on the cutting mechanisms is also unclear.

The purpose of this study is to investigate the cutting mechanisms and the relationship between specific energy of scratching and depth of cut (size effect). The single-point scratch test was carried out on 6061 Al and its composites reinforced by Al2O3 and SiC ceramic particles using a pyramid indenter. The results indicated that the scratch process was composed of rubbing, ploughing, plastic cutting and reinforcement fracture. A simple model was proposed to interpret the apparent size effect. The effect of reinforcement on the specific energy was correlated to the ratio of volume fraction to particle radius. The paper found that for machining MMCs, a larger depth of cut should be used to maintain a lower machining energy, especially for those with a larger ratio of volume fraction to particle radius.

Key words

Metal matrix composites Reinforcement effect Scratching Specific energy size effect Groove topography Depth of cut 

Nomenclature

A

area

C

length or radial crack

C0,C1,C2,C3

constants in Equations (3), (4), (5), and (9)

E

Young's modulus

f

friction coefficient

fv

volume fraction of particles

Ft

tangential force

H

Vicker's hardness

h

depth of cut

Kc

fracture toughness

K

constant in Equation (7)

L

groove length

Le

total edge length of particles, defined in Equation (11)

P

indentation load

p

average contact pressure

R

particle radius

α, α1

constants, defined in Equations (6) and (8)

γ

surface energy of particles

θ

semi-included angle of groove

μ

specific energy

ξ

ratio of particle volume fraction to average radius of particles

σy

yield stress of a composite material

subscript

c

plastic cutting

f

fracture

g

groove surface

p

ploughing

r

rubbing

s

section of groove

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Copyright information

© Kluwer Academic Publishers 1995

Authors and Affiliations

  • Cheng Yan
    • 1
  • Liangchi Zhang
    • 1
  1. 1.Centre for Advanced Materials Technology, Department of Mechanical and Mechatronic EngineeringUniversity of SydneyAustralia

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