Abstract
ABSTRACT This paper presents research results on ultraprecision machining of metal matrix composite (MMC) composed of aluminum matrix and either SiC or A12 03 particles. Ductile-regime machining of both SiC and aluminum was evaluated to improve the surface integrity of the composite. Both polycrystal-line diamond (PCD) and single crystalline diamond (SCD) tools were used to ultraprecision machine the composites at a depth of cut ranging from 0 to 1μm using a taper cut. The feedrate was normalized to the tool nose radius. A model is proposed to calculate the critical depth of cut for MMCs reinforced with either A1203 or SiC. The critical depths of cut were found to be 1 p.m and 0.2 u.m for MMCs reinforced with A12 0 or SiC3, respectively. Both depth of cut and crystallographic direction of the ceramic particles are the sufficient conditions for ductile-regime machining. Although both tools produce similar surface finish, a SCD tool removed the MMC as chips while a PCD tool simply smeared the surface. A diffusion-abrasion mechanism was suspected to cause the surprising wear of the SCD tools when machining the aluminum/SiC composite.
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