Application of Different Cooling Strategies in Drilling of Metal Matrix Composite (MMC)

Abstract:

Conventional cutting fluids are known for being expensive, polluting and a non-sustainable part of modern manufacturing processes. Global industrial trends are leaning towards environmental and health friendly technologies. CO2 cooling is an innovative and sustainable method, capable of replacing conventional oil-based cutting fluids under various conditions. The current study intends to cover the indexable insert drilling of aluminium-silicon carbide (Al-SiC) metal matrix composite (MMC) using different diamond coated carbide inserts. Al-SiC composite containing 20% wt. of SiC was used as workpiece material under different cooling strategies. Response Surface Methodology (RSM) and SEM analysis were incorporated to evaluate the tool performance and to understand the wear development in drilling of MMC. Performance tests were carried out at various cutting data and cooling strategies (external CO2, external emulsion, internal CO2 and internal emulsion) in order to study the output in terms of tool life, surface finish and diameter difference of the holes. The results revealed an advantage in the favour of CO2 cooling concerning tool life, precision and surface finish. Drilling with internal supply of CO2 significantly improves the tool life. The internal supply of CO2 generated the best precision and surface finish compared to the other cooling strategies. The test results clearly indicate that the tool failure for internal CO2 is governed by the flaking of the diamond coating in contrast to a combination of flank wear and flaking for emulsion. The results from the external cooling strategy show that there is no significant difference between emulsion and CO2 while the internal cooling strategy shows that CO2 provides the best results. Since the shape and the surface of the hole are generated by the cutting edge of the periphery insert, the wear development on the periphery insert is the main factor which governs the tool life, surface finish and the diameter difference. This can be explained by the internal CO2 strategy that protects the periphery insert.

• Periodical: Materials Science Forum (Volumes 836-837)
• Pages: 3-12
• DOI: https://doi.org/10.4028/www.scientific.net/MSF.836-837.3
• Online since: January 2016
• Authors: M. Ibrahim Sadik*, Gustav Grenmyr
• Keywords: CO₂, Cryogenic, Cutting Fluids, Drilling, Metal Matrix Composite, Sustainability

References

[1] Venkatesh, V.C., et al, Precision cryogenic drilling, turning and grinding of Ti-64 alloys, Int. J. Precision Technology Vol. 1 Nos. 3/4, (2010), 287-301.

DOI: 10.1504/ijptech.2010.031658

[2] Hollis, W. S, The application and effect of controlled atmospheres in the machining of metals, International Journal of Machine Tool Design and Research, (1961) 59-78.

DOI: 10.1016/0020-7357(61)90044-0

[3] Ghosh, Ranajit, Technology Assessment on Current Advanced Research Projects in Cryogenic Machining. McLean, VA : AMT - The Association for Manufacturing Technology, (2006).

[4] Krämer, Alexander, Lung, Dieter and Klocke, Fritz, High Performance Cutting of Aerospace Materials. Cádiz : Werkzeugmaschinenlabor der RWTH Aachen,. 4th Manufacturing Engineering Society International Conference (2011), 1-9.

[5] Maytal, Ben-Zion and Pfotenhauer, John M. Miniature Joule-Thomson Cyocooling, New York: (2013).

[6] Dionne, Jason J., Schiller, Dan P. and Sorbo, Nelson W. Drilling of Stackup Composite. Eagan Cool Clean Technologies, LLC.

[7] Dix, Martin, et al, Modelling of drilling assisted by cryogenic cooling for higher efficiency CIRP Annals (2014).

[8] Muthukrishnan N, Murugan M, Prahlada Rao K, An investigation on the machinability of Al-SiC metal marix composite using PCD inserts. Int. J. Adv. Manuf Technol 38 (2008), 447-454.

DOI: 10.1007/s00170-007-1111-z

[9] Ding X, Liew W.Y. H, Liu X.D. Evaluation of machining performance of MMC with PCBN and PCD tools. Wear. 259 (2005), 125-1234.

DOI: 10.1016/j.wear.2005.02.094

[10] Karthikeyan R, Ganesan G, Nagarazan R. S, Pai B. C, A critical study on machining of Al/SiC composite. Materials and manufacturing processes. 16 (2001), 47-60.

DOI: 10.1081/amp-100103696

[11] Shaw M.C. Metal cutting principles, Clarendon, Oxford Series on advanced manufacturing 3; (1984).

[12] Lin J.T., Bhattacharyya D, Lane C, Machinability of a silicon carbide reinforced aluminium metal matrix composite. Wear 181-183 (1995), 883-888.

DOI: 10.1016/0043-1648(95)90211-2

[13] Muthukrishnan N, Murugan M, Prahlada Rao K. Machinability issues in turning of Al-Sic (10p) metal matrix composites. Int. J Adv. Manuf Technol 39 (2008), 211-218.

DOI: 10.1007/s00170-007-1220-8

[14] Manna A, Bhattacharyya B, A study on machinability of Al-SiC MMC. J Mater Process Technol 40 (2003), 711-716.

[15] Heath Peter J. Developments in applications of PCD tooling, Journal of Material Processing Technology 116 (2001), 31-38.

[16] Durante S, Rutelli G, Rabezzana F. Aluminum-based MMC machining with diamond-coated cutting tools. Surface and coating technology, 94-95 (1997), 632-640.

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

[17] Hu J, Chou Y. Nanocrystalline diamond coated cutting tools. Material scince and technology (MS&T) September: 16-20 (2007), Detroit, Michigan.

[18] Cronjäger L, Meister D. Machininng of fiber and particle – reinforced Aluminim 1992 Annals of the CIRP 41: 1.

[19] Stoll, A., et al, Modern Cooling Strategies for Machining of High-Temperature Materials, 3rd ICMC - Hybrid Processes, (2014), 299-315.

[20] Rosenberger M. R, Schvezov C. E, Forlerer E, Wear of different aluminium matrix composites under conditions that generate a mechanically mixed layer. Wear 259 (2005), 590-601.

DOI: 10.1016/j.wear.2005.02.003

[21] M. Ibrahim Sadik, E. Jalilian. Characterization and performance evaluation of mono-grain and bi-modal PCD grade in machining of MMC, Procedia CIRP 14 (2014), 200-204.

DOI: 10.1016/j.procir.2014.03.110

[22] Lammer, A., Mechanical properties of polycrystalline diamonds, Materials Science and Technology 4 (1988) 949-955.

DOI: 10.1179/mst.1988.4.11.949

[23] M. Ibrahim Sadik, Wear study and performance evaluation in the machining of MMC with PCD and PCBN tools., MM Science Journal, Special Issue | HSM 2014, 11th International Conference on High Speed Machining, September 11-12, 2014, Prague, Czech Republic.

DOI: 10.1016/j.wear.2005.02.094