Advertisement

Silicon

pp 1–12 | Cite as

Investigations on the Machinability of Al/SiC/RHA Hybrid Metal Matrix Composites

  • Shoba ChintadaEmail author
  • Siva Prasad Dora
  • Raju Prathipati
Original Paper
  • 13 Downloads

Abstract

Hybrid aluminum metal matrix composites (MMC’s) are the emerging materials that gain superior properties in terms of hardness, specific strength, mechanical and physical properties in relation to native metals. These difficult to cut MMC’s are more suited as the state-of-the-art materials giving engineers an opportunity to tailor the material properties in order to adapt for the future requirements. Machining MMC’s is a challenging task and it is even more difficult to machine a hybrid metal matrix composite due to the inclusion of two or more reinforcement particles. Hence, the present work aims in predicting and comparing the experimental data while machining aluminum reinforced with silicon carbide (SiC) and rice husk ash (RHA) particulates. Varying the machining parameters like cutting speed, feed and depth of cut the surface quality, cutting forces and flank wear progression are analyzed. From the outcomes, it is distinguished that, finer surface finish is acknowledged at higher cutting speeds where uninterrupted chips with-out built up edge (BUE) is formed. The cutting force components were found to decrease with increase in cutting speed and increase with varying feed and depth of cut. It was further noticed that the cutting force components decrease with the increase in the % of reinforcement. For the purpose of validation of the cutting force components, Al/6%SiC/6%RHA MMC is selected and validated theoretically with analytical equations. Flank wear tends to increase with cutting speed, feed and depth of cut. Abrasion mechanism is found to be the dominant factor that gives pronounced flank wear. The total volume loss in terms of a quadrature with two body and three body abrasive mechanisms is considered to approve the progression of flank wear and the same was validated with analytical equations.

Keywords

Flank wear Surface roughness Cutting forces Hybrid composites Machinability 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    Soorya Prakash K, Balasundar P, Nagaraja S, Gopal PM, Kavimani V (2016) Mechanical and wear behaviour of Mg-SiC-Gr hybrid composites. Journal of Magnesium and Alloys 4(3):197–206CrossRefGoogle Scholar
  2. 2.
    Soorya Prakash K, Gopal PM, Anburose D, Kavimani V (2016) In press) Mechanical, corrosion and wear characteristics of powder metallurgy processed Ti-6Al-4V/B4C metal matrix composites. Ain Shams Eng J 9:1489–1496.  https://doi.org/10.1016/j.asej.2016.11.003 CrossRefGoogle Scholar
  3. 3.
    Kavimani V, Prakash KS, Gunashri R, Sathish P (2018) Corrosion protection behaviour of r-GO/TiO2 hybrid composite coating on magnesium substrate in 3.5 wt.% NaCl. Prog Org Coat 125:358–364CrossRefGoogle Scholar
  4. 4.
    Kavimani V, Prakash KS (2018) Doping effect of SiC over graphene on dry sliding wear behaviour of Mg/SiC@ r-GO MMCs and its surface characterization. SILICON 10:2829–2843CrossRefGoogle Scholar
  5. 5.
    Basavarajappa S, Chandra Mohan G, Mukund K, Ashwin M, Prabu M (2006) Dry sliding wear behaviour of Al 2219/SiC/Gr hybrid metal matrix composites. J Mater Eng Perform 15(6):668–674CrossRefGoogle Scholar
  6. 6.
    Mahendra KV, Radhakrishna K (2010) Characterization of stir cast Al--Cu--(fly ash + SiC) hybrid metal matrix composites. J Compos Mater 44(8):989–1005CrossRefGoogle Scholar
  7. 7.
    Uvaraja VC, Natarajan N (2012) Comparision on Al6061 and Al7075 alloy with SiC and B4C reinforcement hybrid metal matrix composites. Int J Adv Res Technol 2(2):1–12Google Scholar
  8. 8.
    Surappa MK (2003) Aluminium matrix composites: challenges and opportunities. Sadhana 28(1–2):319–334CrossRefGoogle Scholar
  9. 9.
    Macke A, Schultz BF, Rohatgi P (2012) Metal matrix composites offer the automotive industry an opportunity to reduce vehicle weight, improve performance. Adv Mater Process 170(3):19–23Google Scholar
  10. 10.
    Hoecheng H, Yen S, Ishihara B, Yen BK (1997) Fundamental turning characteristics of tribology favored graphite/aluminium alloy composites. Compos Part A 28A:883–890CrossRefGoogle Scholar
  11. 11.
    Rajmohan T, Palanikumar K, Davim JP (2012) Analysis of surface integrity in drilling metal matrix and hybrid metal matrix composites. J Mater Sci Technol 28(8):761–768CrossRefGoogle Scholar
  12. 12.
    Kannan S, Kishawy HA (2008) Tribological aspects of machining aluminium metal matrix composites. J Mater Process Technol 198(1–3):399–406CrossRefGoogle Scholar
  13. 13.
    Tomac N, Tonnessen K (1992) Machinability of particulate aluminium matrix composites. Anna CIRP 42(1):55–58CrossRefGoogle Scholar
  14. 14.
    Rabinowicz E (1995) Friction and wear of materials2nd edn. Wiley-lnterscience, HobokenGoogle Scholar
  15. 15.
    Venkatesh G, Chakradhar D (2017) Influence of thermally assisted machining parameters on the machinability of Inconel 718 Superalloy. SILICON 9(6):867–877CrossRefGoogle Scholar
  16. 16.
    Adam Khan M, Senthil Kumar A, Thirumalai Kumaran S, Uthayakumar M, Ko TJ (2018) Effect of tool wear on machining GFRP and AISI D2 steel using alumina based ceramic cutting tools. SILICON.  https://doi.org/10.1007/s12633-018-9839-7
  17. 17.
    Ismail OÈ, zdemir UÈ, cen m CÈ, Kazim OÈ n (2000) The effect of forging on the properties of particulate-SiC- reinforced aluminium-alloy composites. Compos Sci Technol 60:411–419CrossRefGoogle Scholar
  18. 18.
    Rabindra Behera S, Das DC, Sutradhar G (2011) Forgeability and machinability of stir cast aluminum alloy metal matrix composites. J Miner Mater Charact Eng 10(10):923–939Google Scholar
  19. 19.
    Alanemea KK, Akintund IB, Olubamb PA, Adewal TM (2013) Fabrication characteristics and mechanical behaviour of rice husk ash – alumina reinforced Al–Mg–Si alloy matrix hybrid composites. J Mater Res Technol 2(1):60–67CrossRefGoogle Scholar
  20. 20.
    Siva Prasad D, Krishna AR (2012) Tribological properties of A356.2/RHA composites. J Mater Sci Technol 28(4):367–372CrossRefGoogle Scholar
  21. 21.
    Siva Prasad D, Rama Krishna A (2012) Effect of heat treatment on the damping behavior of A356.2/RHA composites. Bull Mater Sci 35(6):989–995CrossRefGoogle Scholar
  22. 22.
    Siva Prasad D, Shoba C (2016) Experimental evaluation onto the damping behavior of Al/SiC/RHA hybrid composites. J Mater Res Technol 5(2):123–130CrossRefGoogle Scholar
  23. 23.
    Siva Prasad D, Shoba C, Ramanaiah N (2014) Investigations on mechanical properties of aluminum hybrid composites. J Mater Res Technol 3(1):79–85CrossRefGoogle Scholar
  24. 24.
    Shoba C, Ramanaiah N, Nageswara Rao D (2015) Effect of reinforcement on the cutting forces while machining metal matrix composites, an experimental approach. Int J Eng Sci Technol 18:658–663CrossRefGoogle Scholar
  25. 25.
    Pramanik A, Zhang LCS, Arsecularatne JA (2006) Prediction of cutting forces in the machining of metal matrix composites. Int J Mach Tools Manuf 46(14):1795–1803CrossRefGoogle Scholar
  26. 26.
    Pramanik A, Zhang LC, Arsecularatne JA (2007) An FEM investigation into the behavior of metal matrix composites: tool-particle interaction during orthogonal cutting. Int J Mach Tools Manuf 47(10):1497–1506CrossRefGoogle Scholar
  27. 27.
    Dandekar CR, Shin YC (2009) Multi-step 3-D finite element modeling of subsurface damage in machining particulate reinforced metal matrix composites. Compos A: Appl Sci Manuf 40(8):1231–1239CrossRefGoogle Scholar
  28. 28.
    Kavimani V, Prakash KS (2017) Tribological behaviour predictions of r-GO reinforced Mg composite using ANN coupled Taguchi approach. J Phys Chem Solids 110:409–419CrossRefGoogle Scholar
  29. 29.
    Bhushan RK, Sudhir Kumar Das S (2010) Effect of machining parameters on surface roughness and tool wear for 7075 Al alloy SiC composite. Int J Adv Manuf Technol 50:459–469CrossRefGoogle Scholar
  30. 30.
    Merchant ME (1944) Basic mechanics of metal cutting process. J Appl Mech 11:168–175Google Scholar

Copyright information

© Springer Nature B.V. 2019

Authors and Affiliations

  • Shoba Chintada
    • 1
    Email author
  • Siva Prasad Dora
    • 2
  • Raju Prathipati
    • 2
  1. 1.Department of Industrial EngineeringGITAM (Deemed to be University)VisakhapatnamIndia
  2. 2.Department of Mechanical EngineeringGITAM (Deemed to be University)VisakhapatnamIndia

Personalised recommendations