Flank Wear Progression During Machining Metal Matrix Composites

2005 ◽  
Vol 128 (3) ◽  
pp. 787-791 ◽  
Author(s):  
S. Kannan ◽  
H. A. Kishawy ◽  
M. Balazinski
Keyword(s):  
Tool Wear ◽  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Flank Wear ◽  
Tool Geometry ◽  
Matrix Composites ◽  
Proposed Model ◽  
Three Body Abrasion ◽  
Three Body ◽  
Bar Turning

The machining of composites present a significant challenge to the industry. The abrasive reinforcements cause rapid tool wear and increases the machining cost. The results from machining metal matrix composites (MMCs) with conventional tools show that the main mechanism of tool wear includes two-body abrasion and three-body abrasion. A more flexible method that can be considered as a cost-saving technique is therefore sought for studying the machinability characteristics of these materials. In the previous paper, a methodology for predicting the tool flank wear progression during bar turning of MMCs was presented (Kishawy, Kannan, and Balazinski, Ann. CIRP, 54/1, pp. 55–59). In the proposed model, the wear volume due to two-body and three-body abrasion mechanisms was formulated. Then, the flank wear rate was quantified by considering the tool geometry in three-dimensional (3D) turning. Our main objective in this paper is to validate the proposed model by conducting extensive bar turning experiments under a wide range of cutting conditions, tool geometries, and composite material compositions. The cutting test results showed good agreement between predicted and measured tool wear progression.

Reinforcement and Cutting Tools Interaction during MMC Machining - A Review

2018 ◽  
Vol 22 ◽  
pp. 47-54 ◽  
Author(s):  
Mukesh Chaudhari ◽  
M. Senthil Kumar
Keyword(s):  
Tool Wear ◽  
Metal Matrix Composites ◽  
Process Parameters ◽  
Surface Finish ◽  
Metal Matrix ◽  
Cutting Tools ◽  
Tool Geometry ◽  
Matrix Composites ◽  
Good Surface ◽  
Aerospace Medical

Aluminum based metal matrix composites (AMMC) have found its applications in the automobile, aerospace, medical, and metal industries due to their superior mechanical properties. Fabricated Aluminum based metal matrix composites require machining to improve the surface finish and dimensional tolerance. Machining should be accomplished by good surface finish by consuming lowest energy and less tool wear. This paper reviews the machining of Aluminum based metal matrix composites to investigate the effect of process parameters such as tool geometry, tool wear, surface roughness, chip formation and also process parameters.

Tool Wear in High Speed Milling of SiCp/Al2024 Metal Matrix Composites

2010 ◽  
Vol 33 ◽  
pp. 200-203 ◽  
Author(s):  
Y.J. Wang ◽  
Ming Zhou ◽  
S.N. Huang ◽  
Y.J. Zhang
Keyword(s):  
Tool Wear ◽  
Metal Matrix Composites ◽  
Metal Matrix ◽  
High Speed ◽  
Flank Wear ◽  
Cutting Speed ◽  
Dominant Factor ◽  
Matrix Composites ◽  
High Speed Milling ◽  
Coated Tools

This paper presents an experimental study in high speed milling of metal matrix composites (MMCs). Machining tests were carried out on a high speed milling machine by using TiAlN coated tools and chemical vapour deposition (CVD) diamond coated tools. The cutting tool wear was investigated using an optical microscope and a scanning electron microscope (SEM). The experimental results showed that flank wear is the dominant tool wear mode and abrasive wear and adhesive wear appears to be the main wear mechanism. The build-up edge (BUE) exists during the machining process at a certain speeds. Cutting speed is a dominant factor affecting the flank wear. Generally, high cutting speed lead to severe tool wear, but there seemed to be a certain cutting speed which will cause the least tool wear. Furthermore, there exists a cutting speed limit for both TiAlN coated tools and CVD coated diamond tools in high speed milling of MMCs, beyond which the edge chipping will cause the tool failure very soon.

Experimental and Theoretical Investigations on Tool Wear and Surface Quality in Micro Milling of SiCp/Al Composites Under Dry and MQL Conditions

2018 ◽  
Author(s):  
Ben Deng ◽  
Haowei Wang ◽  
Fangyu Peng ◽  
Rong Yan ◽  
Lin Zhou
Keyword(s):  
Tool Wear ◽  
Metal Matrix Composites ◽  
Surface Quality ◽  
Wear Mechanism ◽  
Metal Matrix ◽  
High Stress ◽  
Micro Milling ◽  
Matrix Composites ◽  
Fe Simulations ◽  
Theoretical Investigations

During the machining processes of ceramic particle reinforced metal matrix composites, the severe tool wear constrains the quality and cost of the parts. This paper presents the experimental and theoretical investigations of the tool wear behavior and surface quality when micro milling the 45vol% SiCp/Al composites under dry and minimum quantity lubrication (MQL) conditions. The results of scanning electron microscope (SEM) and energy dispersive spectrometer (EDS) show that the wear mechanism of diamond coated micro mills are adhesive, abrasion, oxidization, chipping and tipping, even though it has been reported that abrasion is the most important tool wear mechanism when machining particle reinforced metal matrix composites. Compared with dry lubrication condition, the environmentally friendly MQL technique can enhance the tool life and surface roughness, and reduce the cutting force significantly under given cutting parameters. Then, finite element (FE) simulations are employed to investigate chip formation process in micro orthogonal cutting to reveal the effects of reinforced particle on tool wear and surface quality. The FE simulations shows the local high stress, hard reinforced particles in metal matrix, debonded and cracked particles are the key factors leading to the severe tool wear and the unsmoothed surface morphology.

A Phenomenological Model for Tool Wear in Friction Stir Welding of Metal Matrix Composites

2013 ◽  
Vol 44 (8) ◽  
pp. 3757-3764 ◽  
Author(s):  
Tracie J. Prater ◽  
Alvin M. Strauss ◽  
George E. Cook ◽  
Brian T. Gibson ◽  
Chase D. Cox
Keyword(s):  
Friction Stir Welding ◽  
Tool Wear ◽  
Metal Matrix Composites ◽  
Phenomenological Model ◽  
Metal Matrix ◽  
Matrix Composites ◽  
Friction Stir

scholarly journals Tool wear and surface quality of metal matrix composites due to machining: A review

2016 ◽  
Vol 231 (5) ◽  
pp. 739-752 ◽  
Author(s):  
Ferial Hakami ◽  
Alokesh Pramanik ◽  
Animesh K Basak
Keyword(s):  
Tool Wear ◽  
Metal Matrix Composite ◽  
Metal Matrix Composites ◽  
Surface Quality ◽  
Tool Life ◽  
Metal Matrix ◽  
Cutting Tool ◽  
Matrix Composites ◽  
Machined Surface

Higher tool wear and inferior surface quality of the specimens during machining restrict metal matrix composites’ application in many areas in spite of their excellent properties. The researches in this field are not well organized, and knowledge is not properly linked to give a complete overview. Thus, it is hard to implement it in practical fields. To address this issue, this article reviews tool wear and surface generation and latest developments in machining of metal matrix composites. This will provide an insight and scientific overview in this field which will facilitate the implementation of the obtained knowledge in the practical fields. It was noted that the hard reinforcements initially start abrasive wear on the cutting tool. The abrasion exposes new cutting tool surface, which initiates adhesion of matrix material to the cutting tool and thus causes adhesion wear. Built-up edges also generate at lower cutting speeds. Although different types of coating improve tool life, only diamond cutting tools show considerably longer tool life. The application of the coolants improves tool life reasonably at higher cutting speed. Pits, voids, microcracks and fractured reinforcements are common in the machined metal matrix composite surface. These are due to ploughing, indentation and dislodgement of particles from the matrix due to tool–particle interactions. Furthermore, compressive residual stress is caused by the particles’ indentation in the machined surface. At high feeds, the feed rate controls the surface roughness of the metal matrix composite; although at low feeds, it was controlled by the particle fracture or pull out. The coarser reinforced particles and lower volume fraction enhance microhardness variations beneath the machined surface.

Analytical Model of Cutting Force in Micromilling of Particle-Reinforced Metal Matrix Composites Considering Interface Failure

2018 ◽  
Vol 140 (8) ◽  
Author(s):  
Ben Deng ◽  
Lin Zhou ◽  
Fangyu Peng ◽  
Rong Yan ◽  
Minghui Yang ◽  
...  
Keyword(s):  
Cutting Force ◽  
Metal Matrix Composites ◽  
Analytical Model ◽  
Cutting Forces ◽  
Metal Matrix ◽  
Matrix Composites ◽  
Interface Failure ◽  
Edge Radius ◽  
Proposed Model ◽  
Particle Debonding

During the micromachining processes of particle-reinforced metal matrix composites (PMMCs), matrix-particle interface failure plays an important role in the cutting mechanism. This paper presents a novel analytical model to predict the cutting forces in micromilling of this material considering particle debonding caused by interface failure. The particle debonding is observed not only in the processed surface but also in the chip. A new algorithm is proposed to estimate the particles debonding force caused by interface failure with the aid of Nardin–Schultz model. Then, several aspects of the cutting force generation mechanism are considered in this paper, including particles debonding force in the shear zone and build-up region, particles cracking force in the build-up region, shearing and ploughing forces of metal matrix, and varying sliding friction coefficients due to the reinforced particles in the chip-tool interface. The micro-slot milling experiments are carried out on a self-made three-axis high-precision machine tool, and the comparison between the predicted cutting forces and measured values shows that the proposed model can provide accurate prediction. Finally, the effects of interface failure, reinforced particles, and tool edge radius on cutting forces are investigated by the proposed model and some conclusions are given as follows: the particles debonding force caused by interface failure is significant and takes averagely about 23% of the cutting forces under the given cutting conditions; reinforced particles and edge radius can greatly affect the micromilling process of PMMCs.

Sign in / Sign up

Export Citation Format

Share Document