Effect of SiC_p Reinforcement on Machinability of A356 Alloy Metal Matrix Composites

Abstract:

Machining of Aluminum Metal Matrix Composites (AMMCs) is a challenge for manufacturing industries due to their heterogeneous constituents which vary from soft matrix to hard reinforcements and their interfaces. To overcome the difficulties in machining of MMCs, researchers are continuously working to find the optimum process or machining parameters. In this work, End milling studies were carried out in A356 alloy powder-SiC particles (1 μm) in 0, 5, 10, 15 volume % reinforced AMMCs synthesised by vacuum hot pressing (VHP) route.The influence of machining parameters such as cutting speed, feed and depth of cut on the prepared composites in terms of surface roughness (Ra) and material removal rate (MRR) are measured from experimental study. Experiments were conducted as per Taguchi L₁₆ orthogonal array with 4 factors and 4 levels.From the experimental result, it was identified that surface roughness varied from 0.214 μm to 4.115 μm and MRR varied from minimum of 1.11 cm³/min to maximum of 9.65 cm³/min. It is also observed that, MRR increased with increase in machining parameters and reinforcement quantity. Similarly, surface roughness decreased for increase of cutting speed, SiC particle (SiC_p) reinforcement and increased for increase in feed and depth of cut. The optimum condition were observed in higher speed, lower feed and higher depth of cut on MMC with higher SiC content (15%) for getting higher machinability.

• Periodical: Applied Mechanics and Materials (Volume 852)
• Pages: 142-148
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.852.142
• Online since: September 2016
• Authors: K. Jayakumar*
• Keywords: A356 Alloy-SiC Particulate (0, 5, 10, 15%) MMCs, End Milling Study, Metal Removal Rate (MRR), Surface Roughness (Ra), Vacuum Hot Pressing

References

[1] M. Serdar Karakas¸ Adem Acır, Mustafa Ubeyli, Bilgehan Ogel, Effect of cutting speed on tool performance in milling of B4Cp reinforced aluminium metal matrix composites, Journal of Materials Processing Technology. 178 (2006) 241-246.

DOI: 10.1016/j.jmatprotec.2006.04.005

[2] J.M. Torralba, C.E. da Costa, F. Velasco, P/M aluminium matrix composites: an overview, Journal of Materials Processing Technology. 133 (2003) 203-206.

DOI: 10.1016/s0924-0136(02)00234-0

[3] K. Jayakumar, Jose Mathew, M.A. Joseph, R. Suresh Kumar, A.K. Shukla, M.G. Samuel, Synthesis and characterization of A356- SiCp composite produced through vacuum hot pressing, Materials and Manufacturing Processes. 28 (2013) 991-998.

DOI: 10.1080/10426914.2013.773012

[4] K. Jayakumar, Jose Mathew, M.A. Joseph, R. Suresh Kumar, P. Chakravarthy, Processing and end milling behavioural study of A356-SiCp Composite, Materials Science Forum. 710 (2012) 338-343.

DOI: 10.4028/www.scientific.net/msf.710.338

[5] Yifeng Xiong, Wenhu Wang, Ruisong Jiang, Kunyang Lin, Guodong Song, Surface integrity of milling in-situ TiB2 particle reinforced Al matrix composites, International Journal of Refractory Metals and Hard Materials. 54 (2016) 407-416.

DOI: 10.1016/j.ijrmhm.2015.09.007

[6] K. Palanikumar, R. Karthikeyan R, Assessment of factors influencing surface roughness on the machining of Al/SiC particulate composites, Materials and Design. 28 (2007) 1584-1591.

DOI: 10.1016/j.matdes.2006.02.010

[7] A. Arun Premnath, Studies on Machining Parameters while Milling Particle Reinforced Hybrid (Al6061/Al2O3/Gr) MMC, Particulate Science and Technology. 33 (2015) 682-692.

DOI: 10.1080/02726351.2015.1025457