Hybrid machining of metal-matrix composite

Abstract

Particulate SiC-reinforced aluminium (SiCp/Al) metal matrix composite (MMC) is ideal for various aerospace applications thanks to its improved thermo-mechanical properties. However, conventional machining of this material remains a challenge due to its high strength. A newly developed hybrid turning process was used to show tangible improvements in the machining rate and finish quality of the MMC. Experimental analysis on ultrasonically assisted turning (UAT) of SiCp/Al workpiece was performed and compared with conventional turning (CT). Minimum Quantity Lubrication (MQL) was also used in the experiment and added as an experimental parameter. Prior to the experiment, the microstructure of SiCp/Al sample was analysed. An experimental result showed improvement in UAT compared to CT for both cutting force and surface topography. A prospective 2D numerical model was also proposed, which can predict the response of conventional dry machining reasonably. The model can be used to design setups and determine optimized machining parameters to find a solution to current obstacles limiting MMC machining. The experimental cutting force result in CT was compared with the simulation.