Experimental evaluation of grinding forces and surface finish in cylindrical grinding of Al/SiC metal matrix composites

Abstract

This paper deals with an experimental study on the grindability of Al/SiC metal matrix composites (MMCs) in cylindrical grinding. The machining of MMCs is an important area of focus because finishing processes, such as grinding, to obtain a good surface finish and damage-free surfaces, are crucial for the application of these materials. Nevertheless, the grinding of MMCs has received little attention so far, and no detailed study on this subject has been carried out. In the present work, experiments were carried out to study the effect of cylindrical grinding parameters such as wheel velocity (VS), work piece velocity (VW), feed, and depth of cut, and the percentage of SiC volume fraction on the responses, such as grinding force (FT), surface roughness (Ra), and grinding temperature (GT). For each process condition, the average FT, Ra, and GT values were calculated from the three values measured on each ground surface. In the parameter study, the FT and Ra values decrease with an increase in VS and VW, and they increase with an increase in feed and depth of cut. The GT values are scattered in the range of 740–856 °C at the lower and higher levels of grinding variables. In the volume fraction study, the FT, Ra, and GT values increase with an increase in percentage of SiC volume fraction. Surface integrity of the ground surfaces was assessed using a scanning electron microscope (SEM). Cylindrical grinding using a 60 grit Al2O3 wheel at VS 2639 m/min, VW 26.72 m/min, feed 0.06 m/min, and depth of cut 10 µm, is recommended for the Al/SiC composites to obtain finely ground surfaces.