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Tribological and machining characteristics of milling SiCp/Al MMC composites under sustainable cooling conditions

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Abstract

SiC particle-based aluminum matrix (SiCp/Al 20%) is characterized by poor surface quality, high cutting forces, and accelerated tool wear during machining. Environmentally friendly cooling/lubrication (CO2 snow, MQL) can advance the machinability of such composites even at high material removal rates. In this experimental study, milling of SiCp/Al was performed by implementing MQL and CO2 at different cutting speeds and feed per tooth and compared the effect of these lubri-cooling against dry cutting. The experimental results showed the minimum cutting forces, surface roughness, and tool life under MQL followed by CO2 and dry cutting. The microscopic analysis depicted adhesion and abrasion as prevalent wear mechanisms. The EDS analysis (line, point, mapping) revealed relatively less adhesion of aluminum (Al) and silicon (Si) chemical elements under cryogenic compared to dry cutting on tool major cutting edge. Besides, the chip analysis under MQL machining showed discontinuous and serrated-type chips.

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Funding

This work funded by the National Natural Science Foundation of China (NSFC) Research Fund for International Young Scientists (RFIS-1) (Grant No. 52250410358).

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Authors and Affiliations

  1. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China

    Rashid Ali Laghari, Ning He & Muhammad Jamil

  2. Faculty of Mechanical Engineering, Opole University of Technology, Opole, Poland

    Munish Kumar Gupta

  3. Department of Mechanical Engineering, Graphic Era (Deemed to be University), Uttrakhand, India

    Munish Kumar Gupta

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  1. Rashid Ali Laghari
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Rashid Ali Laghari: methodology, validation, investigation, formal analysis, writing and editing. Muhammad Jamil: writing, methodology, and investigation. Ning He: resources and overseeing of analysis. Munish Kumar Gupta: review of experimental setup.

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Laghari, R.A., He, N., Jamil, M. et al. Tribological and machining characteristics of milling SiCp/Al MMC composites under sustainable cooling conditions. Int J Adv Manuf Technol 128, 2613–2630 (2023). https://doi.org/10.1007/s00170-023-12083-9

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