Skip to main content
SpringerLink
Log in

Investigations of flank wear, cutting force, and surface roughness in the machining of Al-6061–TiB2 in situ metal matrix composites produced by flux-assisted synthesis

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

This paper presents the results of an experimental investigation on the machinability of in situ Al-6061–TiB2 metal matrix composite (MMC) prepared by flux-assisted synthesis. These composites were characterized by scanning electron microscopy, X-ray diffraction, and micro-hardness analysis. The influence of reinforcement ratio of 0, 3, 6, and 9 wt.% of TiB2 on machinability was examined. The effect of machinability parameters such as cutting speed, feed rate, and depth of cut on flank wear, cutting force and surface roughness were analyzed during turning operations. From the test results, we observe that higher TiB2 reinforcement ratio produces higher tool wear, surface roughness and minimizes the cutting forces. When machining the in situ MMC with high speed causes rapid tool wear due to generation of high temperature in the machining interface. The rate of flank wear, cutting force, and surface roughness are high when machining with a higher depth of cut. An increase in feed rate increases the flank wear, cutting force and surface roughness.

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

Similar content being viewed by others

References

  1. Allision JE, Gole GS (1993) Metal-matrix composites in the automotive industry: opportunities and challenges. J Min Met Mater Sci 45:19–24

    Google Scholar 

  2. Kuruvilla AK et al (1990) Sripta Metall 24:873

    Article  Google Scholar 

  3. Ma ZY et al (1994) Scripta Metall 31:635

    Article  Google Scholar 

  4. Daniel BS, Murthy VS, Murty GS (1997) Metal-ceramic composites via in-situ methods. J Mater Process Technol 68:132–155

    Article  Google Scholar 

  5. Tjong SC, Ma ZY (2000) Micro structural and mechanical characteristics of in- situ metal matrix composites. Mater Sci Eng R 29:49–113

    Article  Google Scholar 

  6. Lakshmi S, Lu L, Gupta M (1998) In-situ preparation of TiB2 reinforced Al based composites. J Mater Process Technol 73:160–166

    Article  Google Scholar 

  7. Fan T, Yang G, Zhang D (2005) Thermodynamic effect of alloying addition on in-situ reinforced TiB2/Al composites. Metall Mater Trans A 36:225–233

    Article  Google Scholar 

  8. Zhao D, Liu X, LiuY BX (2005) In-situ preparation of Al matrix composites reinforced by TiB2 particles and sub-micron ZrB2. J Mater Sci 40:4365–4368

    Article  Google Scholar 

  9. Christy TV, Murugan N, Kumar S (2010) A comparative study on the microstructures and mechanical properties of Al 6061 Alloy and the MMC Al 6061/TiB2/12P. J Min Mater Charact Eng 9:57–65

    Google Scholar 

  10. Ozcatalbas Y (2003) Chip and built-up edge formation in the machining of in-situ Al4C3–Al composite. Mater Des 24:215–221

    Article  Google Scholar 

  11. Ozcatalbas Y (2003) Investigation of the machinability behavior of Al4C3 reinforced Al-based composite produced by mechanical alloying technique. Comp Sci Technol 63:53–61

    Article  Google Scholar 

  12. Manna A, Bhattacharyya B (2003) A study on machinability of Al/SiC–MMC. J Mater Process Technol 140:711–716

    Article  Google Scholar 

  13. Manna A, Bhattacharyya B (2005) Influence of machining parameters on the machinability of particulate reinforced Al/SiC–MMC. Int J Adv Manuf Technol 25:850–856

    Article  Google Scholar 

  14. Quan YM, Zhou ZH, Ye BY (1999) Cutting process and chip appearance of aluminum matrix composites reinforced by SiC particle. J Mater Process Technol 91:231–235

    Article  Google Scholar 

  15. Ozben T, Kilickap E, Çakır O (2008) Investigation of mechanical and machinability properties of SiC particle reinforced Al–MMC. J Mater Process Technol 198:220–225

    Article  Google Scholar 

  16. Muthukrishnan N, Murugan M, Prahladarao K (2008) An investigation on the machinability of Al–Sic metal matrix composites using PCD insert. Int J Adv Manuf Technol 38:447–454

    Article  Google Scholar 

  17. Muthukrishnan N, Murugan M, Prahladarao K (2008) Machinability issues in turning of Al–Sic (10p) metal matrix composites. Int J Adv Manuf Technol 39:211–218

    Article  Google Scholar 

  18. Lin JT, Bhattacharyya D, Lane C (1995) Machinability of a silicon carbide reinforced aluminum metal matrix composite. Wear 183(2):883–888

    Google Scholar 

  19. Pramanik A, Zhang LC, Arsecularatne JA (2008) Machining of metal matrix composites: effect of ceramic particles on residual stress surface roughness and chip formation. Int J Mach Tools Manuf 48:1613–1625

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Production Engineering, National Institute of Technology, Tiruchirappalli, 620015, India

    V. Anandakrishnan

  2. Department of Mechanical Engineering, Sudharsan Engineering College, Pudukkottai, 622501, India

    A. Mahamani

Authors
  1. V. Anandakrishnan
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. A. Mahamani
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to A. Mahamani.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Anandakrishnan, V., Mahamani, A. Investigations of flank wear, cutting force, and surface roughness in the machining of Al-6061–TiB2 in situ metal matrix composites produced by flux-assisted synthesis. Int J Adv Manuf Technol 55, 65–73 (2011). https://doi.org/10.1007/s00170-010-3042-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-010-3042-3

Keywords

Search

Navigation