Skip to main content
SpringerLink
Log in

An experimental study on milling of high-volume fraction SiCP/Al composites with PCD tools of different grain size

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

Abstract

High-volume fraction SiCP/Al composites have attracted considerable interest as potential materials for electronic packaging. However, due to the existence of hard and brittle SiC particles, high-volume fraction SiCP/Al composite is a kind of difficult-to-machine materials. This paper presents an experimental study on milling high-volume fraction SiCP/Al composites with polycrystalline diamond tools of different grain sizes. A series of milling tests, under three sets of cutting parameters, were conducted on a Mikron UCP 710 high-speed milling machine center. Three polycrystalline diamond (PCD) tools with different grain sizes were used to mill straight grooves. The machined surface quality of the grooves, including surface topography and surface roughness, and tool wear characteristics were analyzed. The results showed that surface roughness increased with feed per tooth (f z) increasing from 5 to 10 μm/z. Chipping and abrasive wear can be observed in cutting tool and chipping is the dominant tool wear mechanism. Tool with grain size of 2~30 μm can achieve the best machined surface quality (Ra 0.3) under cutting parameters of f z = 5 μm/z, a p = 100 μm, and n = 10,000 rpm. But, it has the most severe tool wear in tool tip.

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. Tomac N, Tannessen K, Rasch FO (1992) Machinability of particulate aluminium matrix composites. CIRP Ann Manuf Technol 41:55–58

    Article  Google Scholar 

  2. Teti R (2002) Machining of composite materials. CIRP Ann Manuf Technol 51:611–634

    Article  Google Scholar 

  3. Bian R, He N, Li L, Zhan ZB, Wu Q, Shi ZY (2014) Precision milling of high volume fraction SiCP/Al composites with monocrystalline diamond end mill. Int J Adv Manuf Technol 71:411–419

    Article  Google Scholar 

  4. Zhou L, Huang ST, Wang D, Yu XL (2011) Finite element and experimental studies of cutting process of SiCP/Al composites with PCD tools. Int J Adv Manuf Technol 52:619–626

    Article  Google Scholar 

  5. Jaffery SH, Khan M, Sheikh NA, Mativenga P (2013) Wear mechanism analysis in milling of Ti-6Al-4V alloy. Proc Inst Mech Eng B J Eng Manuf 227(8):1148–1156

    Article  Google Scholar 

  6. Winert K (1993) A consideration of tool wear mechanism when machining metal matrix composites (MMC). CIRP Ann 42:95–98

    Article  Google Scholar 

  7. Andrewes CJE, Feng HY, Lau WM (2000) Machining of an aluminum/SiC composite using diamond inserts. Mater Proc Technol 102:25–29

    Article  Google Scholar 

  8. Pramanik A, Zhang LC, Aersecularatne 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 

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

    Article  Google Scholar 

  10. Davim JP (2001) Turning particulate metal matrix composites: experimental study of the evolution the cutting forces, tool wear and workpiece surface roughness with the cutting time. Proc Inst Mech Eng B J Eng Manuf 215:371–376

    Article  Google Scholar 

  11. Davim JP, Monteiro Baptista AP (2000) Relationship between cutting force and PCD cutting tool in machining silicon carbide reinforced aluminium. J Mater Process Technol 100:417–423

    Article  Google Scholar 

  12. Huang ST, Zhou L, Yu XL, Cui Y (2012) Experimental study of high-speed milling of SiCP/Al composites with PCD tools. Int J Adv Manuf Technol 62:487–493

    Article  Google Scholar 

  13. EI-Gallab M, Sklad M (1998) Machining of Al/SiC particulate metal-matrix composites. Part I: tool performance. Mater Proc Technol 83:151–158

    Article  Google Scholar 

  14. El-Gallab M, Sklad M (1998) Machining of Al/SiC particulate metal matrix composites. Part II: workpiece surface integrity. J Mater Process Technol 83:277–285

    Article  Google Scholar 

  15. El-Gallab M, Sklad M (2000) Machining of Al/SiC particulate metal matrix composites. Part III: comprehensive tool wear models. J Mater Process Technol 101:10–20

    Article  Google Scholar 

  16. Muthukrishnan N, Murugan M, Prahlada Rao K (2008) Machinability issues in turning of Al-SiC (10p) metal matrix composites. Int J Adv Manuf Technol 39:211–218

    Article  Google Scholar 

  17. Muthukrishnan N, Murugan M, Rao KP (2008) An investigation on the machinability of Al-SiC metal matrix composites using PCD inserts. Int J Adv Manuf Technol 38:447–454

    Article  Google Scholar 

  18. Cheung CF, Chan KC, To S, Lee WB (2002) Effect of reinforcement in ultra-precision machining of Al6061/SiC metal matrix composites. Scr Mater 47:77–82

    Article  Google Scholar 

  19. Cheung CF, Lee WB (2000) A theoretical and experimental investigation of surface roughness formation in ultra-precision diamond turning. Int J Mach Tools Manuf 40:979–1002

    Article  Google Scholar 

  20. Wang T, Xie LJ, Wang XB, Jiao L, Shen JW, Xu H, Nie FM (2013) Surface integrity of high speed milling of Al/SiC/65p aluminum matrix composites. Procedia CIRP 8:475–480

    Article  Google Scholar 

  21. Ge YF, Xu JH, Yang H (2010) Diamond tools wear and their applicability when ultra-precision turning of SiCp/2009Al matrix composite. Wear 269:699–708

    Article  Google Scholar 

  22. Ge YF (2007) Fundamental research on ultra-precision turning of SiCP reinforced aluminum matrix composites. Ph.D Thesis, Nanjing University of Aeronautics and Astronautics, China (In Chinese)

Download references

Author information

Authors and Affiliations

  1. Nanjing University of Aeronautics and Astronautics, Nanjing, China

    Yinfei Yang, Qi Wu, Zhongbo Zhan, Liang Li, Ning He & Rabin Shrestha

Authors
  1. Yinfei Yang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Qi Wu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Zhongbo Zhan
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Liang Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Ning He
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Rabin Shrestha
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Yinfei Yang.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Yang, Y., Wu, Q., Zhan, Z. et al. An experimental study on milling of high-volume fraction SiCP/Al composites with PCD tools of different grain size. Int J Adv Manuf Technol 79, 1699–1705 (2015). https://doi.org/10.1007/s00170-015-6901-0

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-015-6901-0

Keywords

Search

Navigation