Abstract
End milling using a solid mill cutter is widely used in aerospace, automotive, biomedical, and chemical industries. However, a comprehensive characterization of chip morphology and micro structural and mechanical behavior of machined chips is lacking in the literature. A series of end milling experiments were conducted for studying the chip morphology of Aluminum metal matrix composite. A new multi-view approach to fully characterize metallurgical aspects of chip& chip morphology including top surface and free surface is taken up in this research paper. Each view of the 3-dimensional (3D) chip has been studied for different characteristics. The variation of chip dimensions with cutting parameters was also determined.
Highlights
The focus of present day is to use materials with low specific weight as it is the best way of reducing the weight of structures
Aluminum alloys as a class are considered as the family of materials offering the highest level of machinability as compared to other families of lightweight metals such as titanium and magnesium alloys
A high speed camera PHOTRON CAM VIEW was used to record the whole process in order to find material removal rate (MRR) and the chips were collected and studied under electron microscope (SEM) to find their length, width, thickness and other micro structural parameters
Summary
The focus of present day is to use materials with low specific weight as it is the best way of reducing the weight of structures. Aluminum alloys are one such example among light weight materials and is used as it has specific characteristics, such as, easy machinability, non corrosive nature and other mechanical and thermal properties. Aluminum alloys as a class are considered as the family of materials offering the highest level of machinability as compared to other families of lightweight metals such as titanium and magnesium alloys. This machinability quantifies the machining performance and may be defined for a specific application by various criteria such as tool life, surface finish, chip evacuation, material removal rate and machine tool power. Characteristics of chip morphology provides a very useful information in tool design
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