Skip to main content
SpringerLink
Log in

Examination of the effect of B4C and GNP reinforcements on machinability in the machining of Al 6061 matrix B4C/GNP reinforced hybrid composites

  • Technical Paper
  • Published:
Journal of the Brazilian Society of Mechanical Sciences and Engineering Aims and scope Submit manuscript

Abstract

In this study, hybrid composite materials with Al 6061 matrix, boron carbide (B4C) and graphene nanoplate (GNP) being reinforced in different ratios were produced with the stir casting method. Afterward, machinability tests were carried out on the hybrid composites produced with the turning method. SNMG 12 04 08 NN LT 10 coded cutting tools were used in turning experiments. Experiments were realized at a fixed cutting depth of 1 mm, in dry machining conditions, using three different cutting speeds and three different feed rates. In the machinability tests, cutting forces and surface roughness values have been measured. At the same time, microscope images of the cutting tool tips were taken. When the data obtained as a result of the experiments were evaluated, it was observed that the cutting forces increased with the increase in the cutting speed, but the surface roughness values decreased to some extent. While the cutting forces increased with the increase in feed rate, there were no significant differences in roughness values and tool wear amounts. It was determined that the most effective parameter on cutting forces, surface roughness values and tool wear were constituted of the changes in B4C reinforcement ratio. It has been observed that the B4C reinforcement phase significantly increases tool wear. Besides, it was evaluated that GNP supplementation had a positive effect on machinability in some machining parameters and showed dry lubricant properties. It was concluded that the porosity and aggregation of the reinforcement element in the composite structure had a negative effect on the machinability properties. In addition, it was evaluated that it would be appropriate to use non-traditional manufacturing methods in addition to conventional machining processes in the processing of highly B4C reinforced composites.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Similar content being viewed by others

References

  1. Shoba CH, Ramanaiah N, Nageswara Rao D (2017) Effect of reinforcement on the cutting forces while machining metal matrix compositese: an experimental approach. Eng Sci Technol Int J 18:658–663. https://doi.org/10.1016/j.jestch.2015.03.013

    Article  Google Scholar 

  2. Nas E, Gökkaya H (2017) Experimental and statistical study on machinability of the composite materials with metal matrix Al/B4C/graphite. Metall Mater Trans 48A:5059–5067. https://doi.org/10.1007/s11661-017-4237-0

    Article  Google Scholar 

  3. Anthony Xavior M, Ajith Kumar JP (2017) Machinability of hybrid metal matrix composite—a review. Procedia Eng 174:1110–1118. https://doi.org/10.1016/j.proeng.2017.01.26

    Article  Google Scholar 

  4. Anshuman Srivastava A (2017) Recent advances in metal matrix composites (MMCs): a review. Biomed J Sci Tech Res 1(2):1–3. https://doi.org/10.26717/BJSTR.2017.01.000236

    Article  Google Scholar 

  5. Thirumalai Kumaran S, Uthayakumar M (2014) Investigation on the machining studies of AA6351-SiC-B4C hybrid metal matrix composites. Int J Mach Mach Mater 15(3/4):174–185. https://doi.org/10.1504/IJMMM.2014.060548

    Article  Google Scholar 

  6. Kala H, Mer KKS, Kumar S (2014) A review on mechanical and tribological behaviors of stir cast aluminum matrix composites. Procedia Mat Sci 6:1951–1960. https://doi.org/10.1016/j.mspro.2014.07.229

    Article  Google Scholar 

  7. Rebba B, Ramanaiah N (2014) Studies on mechanical properties of 2024 Al-B4C composites. Adv Mater Manuf Charact 4(1):42–46. https://doi.org/10.11127/ijammc.2014.03.06

    Article  Google Scholar 

  8. Kumar Sharma D, Sharma M, Upadhyay G (2019) Boron Carbide (B4C) Reinforced Aluminum Matrix Composites (AMCs). Int J Innov Technol Explor Eng 9(1):2194–2203. https://doi.org/10.35940/ijitee.A4766.119119

    Article  Google Scholar 

  9. Niu Z, Cheng K (2019) Investigation on the material removal and surface roughness in ultraprecision machining of Al/B4C/50p metal matrix composites. Int J Adv Manuf Technol 105:2815–2831. https://doi.org/10.1007/s00170-019-04553-w

    Article  Google Scholar 

  10. Nicholls CJ, Boswell B, Davies IJ, Islam N (2017) Review of machining metal matrix composites. Int J Adv Manuf Technol 90:2429–2441. https://doi.org/10.1007/s00170-016-9558-4

    Article  Google Scholar 

  11. Karabulut Ş, Karakoç H, Çıtak R (2016) Influence of B4C particle reinforcement on mechanical and machining properties of Al6061/B4C composites. Compos B 101:87–98. https://doi.org/10.1016/j.compositesb.2016.07.006

    Article  Google Scholar 

  12. Siddesh Kumar NG, Shiva Shankar GS, Basavarajappa S, Suresh R (2017) Some studies on mechanical and machining characteristics of Al2219/nB4C/MoS2 nano-hybrid metal matrix composites. Measurement 107:1–11. https://doi.org/10.1016/j.measurement.2017.05.003

    Article  Google Scholar 

  13. Siddesh Kumar NG, Shiva Shankar GS, Ganesh MN, Vibudha LK (2017) Experimental investigations to study the cutting force and surface roughness during turning of aluminium metal matrix hybrid composites. Mater Today Proc 4(9):9371–9374. https://doi.org/10.1016/j.matpr.2017.06.187

    Article  Google Scholar 

  14. Kannan C, Ramanujam R (2017) Comparative study on the mechanical and microstructural characterisation of AA 7075 nano and hybrid nanocomposites produced by stir and squeeze casting. J Adv Res 8(4):309–319

    Article  Google Scholar 

  15. Sharma VK, Kumar V, Joshi RS (2019) Experimental investigation on effect of RE oxides addition on tribological and mechanical properties of Al-6063 based hybrid composites. Mater Res Express. 6:0865d7. https://doi.org/10.1088/2053-1591/ab2504

    Article  Google Scholar 

  16. Das S, Chandrasekaran M, Samanta S, Kayaroganam P, Davim P (2019) Fabrication and tribological study of AA6061 hybrid metal matrix composites reinforced with SiC/B4C nanoparticles. Ind Lubr Tribol. 71(1):83–89. https://doi.org/10.1108/ILT-05-2018-0166

    Article  Google Scholar 

  17. Hariprasad T, Varatharajan K, Ravi S (2014) Wear characteristics of B4C and Al2O3 reinforced with Al 5083 metal matrix based hybrid composite. Procedia Eng 97:925–929. https://doi.org/10.1016/j.proeng.2014.12.368

    Article  Google Scholar 

  18. Yuvaraj N, Aravindan S, Vipin, (2017) Wear characteristics of Al5083 surface hybrid nano-composites by friction stir processing. Trans Indian Inst Met 70(4):1111–1129. https://doi.org/10.1007/s12666-016-0905-9

    Article  Google Scholar 

  19. Şenel CM, Gürbüz M, Koç E (2015) New generation composites with graphene reinforced aluminum matrix. J Eng Mach 56(669):36–47

    Google Scholar 

  20. Dharsan K, Santhosh Kumar S (2017) An Exploration of the influence in aluminium metal matrix composite reinforced with graphene. Int J Innov Res Sci Eng Technol 6(7):141–142

    Google Scholar 

  21. Md Ali A, Omar MZ, Hashim H, Salleh MS, Mohamed IF (2021) Recent development in graphene-reinforced aluminium matrix composite: a review. Rev Adv Mater Sci 60:801–817. https://doi.org/10.1515/rams-2021-0062

    Article  Google Scholar 

  22. Li M, Gao H, Liang J, Gu S, You W, Shu D, Wang J, Sun B (2018) Microstructure evolution and properties of graphene nanoplatelets reinforced aluminum matrix composites. Mater Charact 140:172–178. https://doi.org/10.1016/j.matchar.2018.04.007

    Article  Google Scholar 

  23. Joel J, Anthony Xavior M (2018) Machinability analysis of aluminum alloy-graphene metal matrix composites using uncoated and dlc-coated carbide insert. Int Mech Eng Congr Expos ASME 2017. https://doi.org/10.1115/IMECE2017-70098

    Article  Google Scholar 

  24. Khan M, Din RU, Basit MA, Wadood A, Husain SW, Akhtar S, Aune RE (2021) Study of microstructure and mechanical behaviour of aluminium alloy hybrid composite with boron carbide and graphene nanoplatelets. Mater Chem Phys 271:124936. https://doi.org/10.1016/j.matchemphys.2021.124936

    Article  Google Scholar 

  25. Abdelatty R, Khan A, Yusuf M, Alashraf A, Shakoor RA (2021) Article effect of silicon nitride and graphene nanoplatelets on the properties of aluminum metal matrix composites. Materials 14(8):1898. https://doi.org/10.3390/ma14081898

    Article  Google Scholar 

  26. Basavarajappa S, Paulo Davim J (2013) Influence of graphite particles on surface roughness and chip formation studies in turning metal matrix composites. Mater Res 16(5):990–996. https://doi.org/10.1590/S1516-14392013005000098

    Article  Google Scholar 

  27. Ajithkumar JP, Anthony Xavior M (2019) cutting force and surface roughness analysis during turning of Al 7075 based hybrid composites. Procedia Manuf 30:180–187. https://doi.org/10.1016/j.promfg.2019.02.026

    Article  Google Scholar 

  28. Na HB, Xu LH, Han GC, Liu SK, Lu LH (2019) Machinability research on the micro-milling for graphene nano-flakes reinforced aluminum alloy. Metals 9(10):1102. https://doi.org/10.3390/met9101102

    Article  Google Scholar 

  29. Joel J, Anthony Xavior M (2019) Optimization on machining parameters of aluminium alloy hybrid composite using carbide insert. Mater Res Express 6(11):116532. https://doi.org/10.1088/2053-1591/ab46c7

    Article  Google Scholar 

  30. Montoya-Dávila M, Pech-Canul MA, Pech-Canul MI (2007) Effect of bi-and trimodal size distribution on the superficial hardness of al/sicp composites prepared by pressureless infiltration. Powder Technol 176:66–71. https://doi.org/10.1016/j.powtec.2007.02.008

    Article  Google Scholar 

  31. Sur G, Şahin Y, Gökkaya H (2005) Production of aluminum based particulate reinforced composites using molten metal mixing and squeeze casting methods. J Fac Eng Arch Gazi Univ 20(2):233–238

    Google Scholar 

  32. Manna A, Bhattacharyya B (2003) A study on machinability ofAl/SiCMMC. J Mater Process Technol 140(1–3):711–716. https://doi.org/10.1016/S0924-0136(03)00905-1

    Article  Google Scholar 

  33. Lin JT, Bhattacharyya B, Kecman D (2003) Multiple regression and neural networks analyses in composites machining. Compos Sci Technol 63(3–4):539–548. https://doi.org/10.1016/S0266-3538(02)00232-4

    Article  Google Scholar 

  34. Venkatesan K, Ramanujam R, Joel J, Jeyapandiarajan P, Vignesh M, Tolia DJ, Venkata Krishna R (2014) Study of cutting force and surface roughness in machining of Al alloy hybrid composite and optimized using response surface methodology. Procedia Eng 97:677–686. https://doi.org/10.1016/j.proeng.2014.12.297

    Article  Google Scholar 

  35. Verma N, Vettivel SC, Rao PS, Zafar S (2019) Processing tool wear measurement using machine vision system and optimization of machining parameters of boron carbide and rice husk ash reinforced AA 7075 hybrid composite. Mater Res Express 6(8):865f3. https://doi.org/10.1088/2053-1591/ab2509

    Article  Google Scholar 

  36. Hameed Najem S (2013) Machinability of Al-2024 reinforced with Al2O3 and/or B4C. Univ Babylon J 21:84–96

    Google Scholar 

  37. Kannan S, Kishawy HA (2008) Tribological aspects of machining aluminium metal matrix composites. J Mater Process Technol 198:399–406. https://doi.org/10.1016/j.jmatprotec.2007.07.021

    Article  Google Scholar 

  38. Kılıçkap E, Çakır O, Aksoy M, İnan A (2005) Study of tool wear and surface roughness in machining of homogenised SiC-p reinforced aluminium metal matrix composite. J Mater Process Technol 164–165:862–867. https://doi.org/10.1016/j.jmatprotec.2005.02.109

    Article  Google Scholar 

  39. Özcatalbaş Y (2003) Chip and built-up edge formation in the machining of in situ Al4C3–Al composite. Mater Des 24(3):215–221. https://doi.org/10.1016/S0261-3069(02)00146-2

    Article  Google Scholar 

  40. Gökkaya H, Nalbant M (2007) Investigating the effects of cutting speeds over the built-up layer and built-up edge formation with SEM. J Fac Eng Arch Gazi Univ 22(3):481–488

    Google Scholar 

  41. Ajithkumar JP, Anthony Xavior M (2019) Flank and crater wear analysis during turning of Al 7075 based hybrid composites. Mater Res Express 6:086560. https://doi.org/10.1088/2053-1591/ab196e

    Article  Google Scholar 

  42. Na HB, Xu LH, Han GC, Liu SK, Lu LH (2019) Machinability research on the micro-milling for graphene nano-flakes reinforced aluminum alloy. Metals 9:1102. https://doi.org/10.3390/met9101102

    Article  Google Scholar 

  43. Akgün M, Demir H (2021) Experimental and numerical analysis of the effect of cutting parameters on cutting force and chip formation in turning process. El-Cezeri 8(2):897–908. https://doi.org/10.31202/ecjse.892705

    Article  Google Scholar 

  44. Memiş F, Turgut Y (2020) Experimental ınvestigation of surface roughness and cutting forces in machining of AISI 2205 duplex stainless steel on CNC lathe. Manuf Technol Appl 1(1):22–33

    Google Scholar 

  45. Dhand V, Rhee KY, Kim HJ, Jung DH (2013) A comprehensive review of graphene nanocmposites: research satatus and trends. J Nanomater 763953:1–14. https://doi.org/10.1155/2013/763953

    Article  Google Scholar 

  46. Chen LY, Konishi H, Fehrenbacher A, Ma C, Xu JQ, Choi H, Xu HF, Pfeferkorn FE, Li XC (2012) Novel nanoprocessing route for bulk graphene nanoplatelets reinforced metal matrix nanocomposites. Scripta Mater 67(1):29–32. https://doi.org/10.1016/j.scriptamat.2012.03.013

    Article  Google Scholar 

  47. Bastwros M, Kim GY, Zhang CZK, Wang S, Tang X (2014) Effect of ball milling on graphene reinforced Al6061 composite fabricated by semi-solid sintering. Compos Part: B 60:111–118. https://doi.org/10.1016/j.compositesb.2013.12.043

    Article  Google Scholar 

  48. Bartolucci SF, Paras J, Rafiee MA, Rafiee J, Lee S, Kapoor D, Koratkar N (2011) Graphene-aluminum nanocomposites. Mater Sci Eng A 528(27):7933–7937. https://doi.org/10.1016/j.msea.2011.07.043

    Article  Google Scholar 

  49. Pérez-Bustamante R, Bolaños-Morales D, BonillaMartínez J, Estrada-Guel I, Martínez-Sánchez R (2014) Microstructural and hardness behavior of graphene-nanoplatelets/aluminum composites synthesized by mechanical alloying. J Alloy Compd 615(1):578–582. https://doi.org/10.1016/j.jallcom.2014.01.225

    Article  Google Scholar 

  50. Wang J, Li Z, Fan G, Pan H, Chen Z, Zhang D (2012) Reinforcement with graphene nanosheets in aluminium matrix composites. Scripta Mater 66(8):594–597. https://doi.org/10.1016/j.scriptamat.2012.01.012

    Article  Google Scholar 

  51. Pul M (2013) The effect of MgO ratio on surface roughness in Al-MgO composites. Mater Manuf Process 28:963–968. https://doi.org/10.1080/10426914.2012.677907

    Article  Google Scholar 

  52. Sekmen M, Günay M, Şeker U (2015) Effect on formations of built-up edge and built-up layer, surface roughness of cutting speed and rake angle in the machining of aluminum alloys. J Polytech 18(3):141–148. https://doi.org/10.2339/2015.18.3141148

    Article  Google Scholar 

  53. Özlü B, Akgün M, Demir H (2019) Analysis and optimization of effects on surface roughness of cutting parameters on turning of aa6061 alloy. Gazi J Eng Sci 5(2):151–158. https://doi.org/10.30855/gmbd.2019.02.04

    Article  Google Scholar 

  54. Shoba C, Prasad DS, Sucharita A, Abishek M, Koundinya MS (2018) Investigations of surface roughness power consumption, MRR and tool wear while turning hybrid composites. Mater Today Proc 5(8):16565–16574. https://doi.org/10.1016/j.matpr.2018.06.012

    Article  Google Scholar 

  55. Kannan S, Kishawy HA (2008) Tribological aspects of machining aluminium metal matrix composites. J Mater Process Technol 198(1–3):399–406. https://doi.org/10.1016/j.jmatprotec.2007.07.021

    Article  Google Scholar 

  56. Bozkurt S (2019) Investigation of the effects of cutting parameters on geometric tolerances and surface roughness of AA7075 T651 aluminum alloy during the turning process. Dissertation, University of Karabuk, Turkey

Download references

Author information

Authors and Affiliations

  1. Kırıkkale Vocational School, Department of Electricity and Energy, Kırıkkale University, Kırıkkale, Turkey

    Muharrem Pul

  2. Faculty of Technology, Department of Manufacturing Engineering, Gazi University, Ankara, Turkey

    Selçuk Yağmur

Authors
  1. Muharrem Pul
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Selçuk Yağmur
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Muharrem Pul.

Ethics declarations

Conflict of interest

Authors do not have any financial or any other interests or obligations in the matter of publications of this research manuscript.

Additional information

Technical Editor: Izabel Fernanda Machado.

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Pul, M., Yağmur, S. Examination of the effect of B4C and GNP reinforcements on machinability in the machining of Al 6061 matrix B4C/GNP reinforced hybrid composites. J Braz. Soc. Mech. Sci. Eng. 44, 469 (2022). https://doi.org/10.1007/s40430-022-03776-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s40430-022-03776-5

Keywords

Search

Navigation