Processing and End Milling Behavioural Study of A356-SiC_p Composite

Abstract:

Machining process such as milling receives less attention in the study of machinability of composites due to its interrupted cutting and the complexity of the process. In the present study, A356 aluminium alloy powder reinforced with 10 volume % SiC particles of various sizes (1,12.5 and 25 µm) were synthesized by vacuum hot pressing method and the effect of particle size on the composites were analysed for its mechanical properties and machinability. End milling of these composites were carried out and the surface roughness and resultant cutting force were analysed with the change of machining parameters and varying SiC particle sizes. The minimum cutting force and surface roughness were obtained for a finer particle (1 µm) reinforced composite with higher cutting speed, low feed and depth of cut.

• Periodical: Materials Science Forum (Volume 710)
• Pages: 338-343
• DOI: https://doi.org/10.4028/www.scientific.net/MSF.710.338
• Online since: January 2012
• Authors: K. Jayakumar, Jose Mathew, M.A. Joseph, R. Suresh Kumar, P. Chakravarthy
• Keywords: A356 Al-SiC Metal Matrix Composites, Box-Behnken Experimental Design, Cutting Force, End Milling, Surface Roughness (SR), Vacuum Hot Press Method

References

[1] M. Kok, Production and mechanical properties of Al2O3 particle-reinforced 2024 aluminum alloy composites, J. Mater. Proc. Tech. 161 (2005) 381–387.

DOI: 10.1016/j.jmatprotec.2004.07.068

[2] Mohammed T. Hayajneh, Adel Mahmood Hassan, Ahmad Turki Mayyas, Artificial neural network modeling of the drilling process of self-lubricated aluminum/alumina/graphite hybrid composites synthesized by P/M technique, J.Alloys and Compounds. 478 (2009) 559-565.

DOI: 10.1016/j.jallcom.2008.11.155

[3] Mehdi Rahimian, Nader Parvin, Naser Ehsani, Investigation of particle size and amount of alumina on microstructure and mechanical properties of Al matrix composite made by powder metallurgy. Materials Science and Engineering A. 527 (2010) 1031–1038.

DOI: 10.1016/j.msea.2009.09.034

[4] A. Slipenyuk, V.Kuprin, Milman Yu, V. Goncharuk, J. Eckert, Properties of P/M processed particle reinforced metal matrix composites specified by reinforcement concentration and matrix-to- reinforcement particle size ratio, Acta Mater. 54 (2006) 157–166.

DOI: 10.1016/j.actamat.2005.08.036

[5] Song Min, Effect of volume fraction of SiC particles on mechanical properties of SiC/Al composites, Trans.Nonferrous Met.Soc.China. 19 (2009) 1400-1404.

DOI: 10.1016/s1003-6326(09)60040-6

[6] S.Durante, G. Rutelli, F. Rabezzana, Aluminum-based MMC machining with diamond-coated cutting tools, Surf.Coat. Technol. 94-95 (1997) 632-638.

DOI: 10.1016/s0257-8972(97)00521-5

[7] P.G. Benardos, G.C. Vosniakos, Prediction of surface roughness in CNC face milling using neural networks &Taguchi's design of experiments, Rob.Comp. Integ. Manu.18 (2002) 343–354.

DOI: 10.1016/s0736-5845(02)00005-4

[8] N. Suresh Kumar Reddy, Shin Kwang-Sup, Minyang Yang, Experimental study of surface integrity during end milling of Al/SiC particulate MMC, J. Mater. Proc. Tech. 201 (2008) 574–579.

DOI: 10.1016/j.jmatprotec.2007.11.280

[9] B. Ganesh babu,V. Selladurai, R. Shanmugam, Analytical modelling of cutting forces of end milling operation on Al-SiCp MMC using RSM, J. Engg and Applied Sciences.3 (2008) 5-18.

[10] R. Karthikeyan, K. Raghukandan, R.S. Naagarazan, B.C. Pai, Optimizing the Milling Characteristics of Al-SiC Particulat composites, Metals and Materials. 6 (2000) 539-547.

DOI: 10.1007/bf03028096