Skip to main content
SpringerLink
Log in

Analysis of Acoustic Emission Signal to Characterization the Damage Mechanism During Drilling of Al-5%SiC Metal Matrix Composite

  • Original Paper
  • Published:
Silicon Aims and scope Submit manuscript

Abstract

Tool wear drives poor surface quality, dimensional error in the workpiece, and unexpected sudden tool failure during the machining process. Thus, detection of tool wear is essential to increase the workpiece quality and extend tool life. In this view, acoustic emission technique (AET) was employed to investigate the tool wear characteristics for different tool geometries during drilling of Al-5%SiC metal matrix composite (MMC). The dry drilling experiments were performed for different cutting speeds and feed rates ranging from 600-1200 rpm and 0.07–0.17 mm/rev, respectively. The high strength steel (HSS) tool with different point angles (90°, 118°, and 135°) was used for the drilling tests. The captured acoustic emission (AE) signals were analyzed in time domain, frequency domain, and time-frequency domain. AE count, energy, peak amplitude, and root mean square voltage (AERMS) were correlated with cutting parameters (spindle speed and feed rate). The Fast Fourier Transform (FFT) and Continuous Wavelet Transform (CWT) of AE signals could identify the predominant peak frequency and time-frequency spectrum. The relationship between tool wear and AE parameter (wavelet coefficient) for different tool geometries was studied. Wavelet packet transform (WPT) was utilized to extract various AE source features present in the signals. The WPT results could distinguish different frequency components and the related damage mechanisms involved in the drilling process. The damage in the cutting tool and drilled workpiece were also characterized using a scanning electron microscope (SEM).

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. Chawla N, Shen YL (2001) Mechanical behaviour of particle reinforced metal matrix composites. Adv Eng Mater 3:357–370

    Article  CAS  Google Scholar 

  2. Fenghong C, Chang C, Wang Z, Muthuramalingam T, Anbuchezhiyan G (2019) Effects of silicon carbide and tungsten carbide in aluminium metal matrix composites. Silicon. 11:2625–2632. https://doi.org/10.1007/s12633-018-0051-6

    Article  CAS  Google Scholar 

  3. Khadem SA, Nategh S, Yoozbashizadeh H (2011) Structural and morphological evaluation of Al-5vol.% SiC nanocomposite powder produced by mechanical milling. J Alloys Compd 509:2221–2226

    Article  CAS  Google Scholar 

  4. Torres B, Lieblich H, Ibanez J, Garcia-Escorial A (2002) Mechanical properties of some PM aluminide and silicide reinforced 2124 aluminum matrix composites. Scripta Mater 47:45–50

    Article  CAS  Google Scholar 

  5. Ibrahim IA, Mohamed FA, Lavernia E (1991) Particulate reinforced metal matrix composites-a review. J Mater Sci 26:1137

    Article  CAS  Google Scholar 

  6. Bhushan RK, Kumar S, Das S (2010) Effect of matrix/reinforcement particle size ratio (PSR) on the mechanical properties of extruded Al-SiC composites. Int J Adv Manuf Technol 50:459–469

    Article  Google Scholar 

  7. Kilickap E, Cakir O, Aksoy M, Inan A (2005) Study of tool wear and surface roughness in machining of homogenized SiC-p reinforced aluminum metal matrix composite. J Mater Proc Technol 164:862–867

    Article  Google Scholar 

  8. Suresh Kumar S, Uthayakumar M, Thirumalai Kumaran S, Parameswaran P, Haneef TK, Mukhopadhyay CK, Rao BPC (2018) Performance monitoring of WEDM using online acoustic emission technique. Silicon 10(6):2635–2642

    Article  Google Scholar 

  9. Lin SC, Ting CJ (1995) Tool wear monitoring in drilling using force signals. Wear 180(1–2):53–60

    Article  Google Scholar 

  10. Orhan S, Er AO, Camuşcu N, Aslan E (2007) Tool wear evaluation by vibration analysis during end milling of AISI D3 cold work tool steel with 35 HRC hardness. NDT & E International 40(2):121–126

    Article  CAS  Google Scholar 

  11. Kishawy HA, Hegab H, Umer U, Mohany (2018) Application of acoustic emission in machining process: analysis and critical review. Int J Adv Manuf Technol 98:1391–1407

    Article  Google Scholar 

  12. Li X (2002) A brief review on acoustic emission method for tool wear monitoring during turning. Int J Mach Tools Manuf 42:157–165

    Article  Google Scholar 

  13. Webster J, Ding WP, Lindsay R (1996) Raw acoustic emission signal analysis of grinding process. CIRP Ann Manuf Technol 45:335–340

    Article  Google Scholar 

  14. Saini DP, Park YJ (1996) Quantitative model of acoustic emissions in orthogonal cutting operations. J Mater Proc Technol 58:343–350

    Article  Google Scholar 

  15. Baccar D, Soffker D (2015) Wear detection by means of wavelet based acoustic emission analysis. J Mech Syst Sign Proc 61:198–207

    Article  Google Scholar 

  16. Liao Z, Dragos A, Axinte (2016) On monitoring chip formation, penetration depth and cutting malfunctions in bone micro-drilling via acoustic emission. J Mater Process Technol 229:82–93

    Article  Google Scholar 

  17. Jantunen E (2002) A summary of methods applied to tool condition monitoring in drilling. Int J Mach Tools Manu 42:997–1010

    Article  Google Scholar 

  18. Karimi NZ, Minak G, Kianfar P (2015) Analysis of damage mechanisms in drilling of composite materials by acoustic emission. Compos Struct 131:107–114

    Article  Google Scholar 

  19. Zuo L, Zuo D, Zhu Y, Wang H (2018) Acoustic emission analysis for tool wear state during friction stir joining of SiCp/Al composite. Int J Adv Manuf Technol 99:1361–1368

    Article  Google Scholar 

  20. Karakus M, Perez S (2014) Acoustic emission analysis for rock-bit interactions in impregnated diamond core drilling. Int J Rock Mech Min Sci 68:36–43

    Article  Google Scholar 

  21. Mukhopadhyay CK, Jayakumar T, Raj B, Venugopal S (2012) Statistical analysis of acoustic emission signals generated during turning of a metal matrix composite. J Braz Soc Mech Sci Eng 34:145–154

    Article  Google Scholar 

  22. Prakash M, Kanthababu M, Rajurkar KP (2014) Investigation on the effects of tool wear on chip formation mechanism and chip morphology using acoustic emission signal in the microend milling of aluminum alloy. Int J Adv Manuf Technol 77:1499–1511

    Article  Google Scholar 

  23. Kakade S, Vijayaraghavan L, Krishnamurthy R (1994) In-process tool wear and chip-form monitoring in face milling operation using acoustic emission. J Mater Process Technol 44:207–214

    Article  Google Scholar 

  24. Ravishankar SR, Murthy CRL (2000) Characteristics of AE signals obtained during drilling composite laminates. NDT & E International 33:341–348

    Article  Google Scholar 

  25. Olufayo O, Abou-El-Hossein K (2015) Tool life estimation based on acoustic emission monitoring in end-milling of H13 mould-steel. Int J Adv Manuf Technol 98:1391–1407

    Google Scholar 

  26. Inegbenebor AO, Bolu CA, Babalola PO, Inegbenebor AI, Fayomi OSI (2016) Aluminum silicon carbide particulate metal matrix composite development via stir casting processing. Silicon 10:343–347

    Article  Google Scholar 

  27. Shivi R (2007) Introduction to applied statistical signal analysis3rd edn. Academic Press, San Diego

    Google Scholar 

  28. Arul S, Vijayaraghavan L, Malhotra SK (2007) Online monitoring of acoustic emission for quality control in drilling of polymeric composites. J Mater Process Technol 185:184–190

    Article  CAS  Google Scholar 

  29. Soman KP, Ramachandran KI (2005) Insight into wavelets from theory to practice2nd edn. Prentice-Hall of India Pvt Limited

  30. Heidary H, Ahmadi M, Rahimi A, Minak G (2012) Wavelet-based acoustic emission characterization of residual strength of drilled composite materials. J Comp Mater 47:2897–2908

    Article  Google Scholar 

  31. Sayar H, Azadi M, Ghasemi-Ghalebahman A, Jafari SM (2018) Clustering effect on damage mechanism in open-hole laminated carbon/epoxy composite under constant tensile load rate, using acoustic emission. Compos Struct 20:41–11

    Google Scholar 

  32. Marec A, Thomas JH, Guerjouma E (2008) Damage characterization of polymer –based composite materials: multivariable analysis and wavelet transform for clustering acoustic emission data. Mech Syst Signal Process 22:1441–1464

    Article  Google Scholar 

  33. Bhuiyan MSH, Choudhury IA, Dahari M, Nukman Y, Dawal AZ (2016) Application of acoustic emission sensor to investigate the frequency of tool wear and plastic deformation in tool conditioning monitoring. Measurement 92:208–217

    Article  Google Scholar 

  34. Taskensen A, Kutukde K (2013) Analysis and optimization of drilling parameters for tool wear and hole dimensional accuracy in B4C reinforced Al-alloy. Trans Nonferrous Met Soc China 23:2524–2536

    Article  Google Scholar 

  35. Zitoune R, Krishnaraj V, Almabouacif BS, Collombet F, Sima M, Jolin A (2012) Influence of machining parameters and new nano-coated tool on drilling performance of CFRP/aluminum sandwich. Composites Part B43:1480–1488

    Article  Google Scholar 

Download references

Acknowledgements

The authors are thankful to Dr. A.K Bhaduri, Director, IGCAR and Dr. G. Amarendra, Director, Metallurgy and Materials Group, IGCAR, for support. The authors are thankful to Dr. S. Murugan, Head, RIMMD, IGCAR for helping to carry out the drilling experiment. The authors are also thankful to Dr. Amirthapandian, MSG, IGCAR for helping to carry out the SEM studies.

Author information

Authors and Affiliations

  1. Non-destructive Evaluation Division, Metallurgy and Materials Group, Indira Gandhi Centre for Atomic Research, Kalpakkam, Tamil Nadu, 603102, India

    K. Thirukkumaran & C. K. Mukhopadhyay

  2. Homi Bhabha National Institute, Kalpakkam, Tamil Nadu, 603102, India

    K. Thirukkumaran & C. K. Mukhopadhyay

Authors
  1. K. Thirukkumaran
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. C. K. Mukhopadhyay
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to C. K. Mukhopadhyay.

Additional information

Publisher’s Note

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

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Thirukkumaran, K., Mukhopadhyay, C.K. Analysis of Acoustic Emission Signal to Characterization the Damage Mechanism During Drilling of Al-5%SiC Metal Matrix Composite. Silicon 13, 309–325 (2021). https://doi.org/10.1007/s12633-020-00426-0

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12633-020-00426-0

Keywords

Search

Navigation