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A critical review on tool wear mechanism and surface integrity aspects of SiCp/Al MMCs during turning: prospects and challenges

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Abstract

Among several kinds of metal matrix composite materials (MMCs), such as silicon-based reinforced aluminum matrix (SiCp/Al) composites have become the most valuable composite material due to their various applications in industries, sports equipment, electrons, and automotive. Due to the presence of hard ceramic reinforcements, the SiCp/Al composite is considered a difficult-to-cut material, which leads to significant hindrances in machining operations together with increased tool wear, cutting force, and degradation of machined surface quality. The present review is focused on the recent advancements in turning process of metal matrix composites. An attempt is made to comprehensively analyze and identify the influencing factors on the machinability of metal matrix composites (MMCs). The main purpose of this review is to cover the topics such as the recent trends in turning and hybrid turning processes of MMCs, tool wear and its mechanisms, tool selection, the effect of cutting parameters, surface integrity, SiCp/Al composite properties and reinforcement effect, chip formation mechanisms, and different modeling approaches used in particle-reinforced MMCs machining process. Finally, some research gaps and future directions are suggested that could lead to efficient machining of particle-reinforced MMCs.

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Acknowledgements

The authors acknowledge partial support of the Interdisciplinary Research Center for Intelligent Manufacturing and Robotics at King Fahd University of Petroleum and Minerals in Saudi Arabia.

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Authors and Affiliations

  1. Interdisciplinary Research Center for Intelligent Manufacturing and Robotics King, Fahd University of Petroleum and Minerals, Dhahran, 31261, Saudi Arabia

    Rashid Ali Laghari, Syed Sohail Akhtar & Samir Mekid

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

    Muhammad Jamil

  3. Department of Computer Science, Sindh Madressatul Islam University, Karachi, Pakistan

    Asif Ali Laghari

  4. Department of Mechatronics Engineering, University of Chakwal (UoC), Chakwal, 48800, Pakistan

    Aqib Mashood Khan

  5. Mechanical Engineering Department, King Fahd University of Petroleum and Minerals, Dhahran, 31261, Saudi Arabia

    Syed Sohail Akhtar & Samir Mekid

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Contributions

Rashid Ali Laghari: writing original draft, design and conceptualization, validation, and project administration.

Muhammad Jamil: editing and writing—original draft; review of the original draft.

Asif Ali Laghari: drawing and designing figures and conceptualization, review of draft, and validation.

Aqib Mashood Khan: data curation; writing—original draft; and validation.

Syed Sohail Akhtar: data curation; formal analysis; visualization; and writing—original draft.

Samir Mekid: data curation; formal analysis; software; and writing—original draft.

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Laghari, R.A., Jamil, M., Laghari, A.A. et al. A critical review on tool wear mechanism and surface integrity aspects of SiCp/Al MMCs during turning: prospects and challenges. Int J Adv Manuf Technol 126, 2825–2862 (2023). https://doi.org/10.1007/s00170-023-11178-7

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  • DOI: https://doi.org/10.1007/s00170-023-11178-7

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