Evaluation of Surface Integrity during Machining with Different Tool Grades of Sic_p/Al-Si Composites Produced by Powder Metallurgy

Abstract:

MMCs components are mostly produced using near net shape manufacturing methods and are subsequently machined to the final dimensions and surface finishes. The MMCs consist of extremely hard reinforcing particles and pose considerable challenges due to the poor machinability and severe wear of the cutting tool. In this study, cutting performance of WC, CBN and PCD cutting tools were investigated with respect to surface roughness during machining of 10 wt % SiCp reinforced Al-Si alloy matrix composites produced by powder metallurgy (PM) method. Average surface roughness (Ra) corresponding to each machining condition was measured. After the machining process the worn insert tips were examined under the scanning electron microscope (SEM). Chip geometry and machined surface photographs have been taken by optical microscopy. The experimental results showed that surface roughness decreased with increasing cutting speed for all of cutting tool materials. The best surface integrity was occurred after the machining with PCD insert at the highest cutting speed employed.

• Periodical: Materials Science Forum (Volume 672)
• Pages: 319-322
• DOI: https://doi.org/10.4028/www.scientific.net/MSF.672.319
• Online since: January 2011
• Authors: Mustafa Günay, Ulvi Şeker
• Keywords: Al-Si Alloy, Metal Matrix Composite (MMC), Powder Metallurgy (PM), Surface Integrity

References

[1] E.S. Lee: Int. Journal Adv. Manufacturing Technology. 16 (2000), p.700.

[2] N. Chawla & K.K. Chawla: Metal matrix composites (Springer Science Business, Boston 2006).

[3] Hyo S. Lee, Jae S. Yeo, Soon H. Hong, Duk J. Yoon, Kyung H. Na: J Mater Process Tech. 113 (2001), p.202.

[4] K.N. Prabhu, B.N. Ravishankar, Materials Science Eng. A: 360 (2003), p.293.

[5] C.J.E. Andrewes, H.Y. Feng, W.M. Lau: J Mater Process Tech. 102 (2000), p.25.

[6] O. Quigley, J. Monaghan, P. O'Reilly: J Mater Process Tech. 43 (1994), p.21.

[7] I. Ciftci, M. Turker, U. Seker: Wear. 257 (2004), p.1041.

[8] N.P. Hung, F.Y.C. Boey, K.A. Khor, Y.S. Phua, H.F. Lee: J Mater Process Tech. 56 (1996), p.966.

[9] M. Günay: PhD Thesis, Gazi University. Turkey. (2009).

[10] S. Sundaram, P. Senthilkumar, A. Kumaravel and N. Manoharan: ARPN Journal of Engineering and Applied Sciences, 3 (4) (2008).

[11] J.P. Davim: J Mater Process Tech. 128 (2002), p.100.

[12] S. Kannan, H.A. Kishawy: Int J Mach Tool Manufact: 46 (2006), p. (2017).

[13] Uday A. Dabade, Suhas S. Joshi, R. Balasubramaniam, V.V. Bhanuprasad: J Mater Process Tech. 192–193 (2007), p.166–174.

[14] M. Günay, E. Bahceci, U. Şeker, M. Türker: 5th Int. Powder Metallurgy Conference, Turkey, (2008).

[15] S. Kalpakjian, S.R. Schmid: Manufacturing Engineering and Technology (Pearson Prentice Hall 2006).