Analysis of Orthogonal Cutting of Aluminium-based Composites

Abstract

A turning test on aluminium-based metal-matrix composites (MMCs) (aluminium-30% silicon carbide) was performed with K-20 carbide tool material and wear patterns and the wear land growth rates were analysed to evaluate the wear characteristics and to classify the relationship between the physical (mechanical) properties and the flank wear of cutting tools. The study was also extended to the machining aspects and the width of cuts on MMCs and the influence of various cutting parameters. The experiments were conducted to measure the temperature along the cutting tool edge using thermocouple at various cutting speeds, and depth of cuts, keeping the feed rate constant while turning with K-20 carbide cutting tool. The finite-element method was used to simulate the orthogonal cutting of aluminium-based MMCs. The heat generation at the chip-tool interface, frictional heat generation at the tool flank, and the heat generation at the work tool interface were calculated analytically and imposed as boundary conditions. The analysis of the steady-state heat transfer was carried out and the temperature distribution at cutting edge, shear zone, and interface regions have been reported.