Abstract
This study presents an experimental investigation on surface roughness and chip formation in turning of Al 2219/15SiCp and Al 2219/15SiCp-3Gr (hybrid) composites. Experiments were conducted with different cutting conditions using carbide, coated carbide and polycrystalline diamond (PCD) tools. The results reveal that the surface roughness values are less for coated carbide tools compared to carbide and are minimum for PCD tools. The incorporation of graphite in Al 2219/15SiCp composite increases the surface roughness. This is due to smearing and removal of softer and amorphus graphite particles on the surface of the specimen, creates pits on the machined surface which increases the surface roughness values. The graphitic composite produced discontinuous chips leads to easy machining. PCD tool performs better than carbide and coated carbide tools.
Highlights
Composite materials exhibits better properties compared to conventional alloys in various applications as they have high specific strength, stiffness and better wear resistance, metal matrix composites are one among them
This is due to the presence of hard ceramic particles in composites, which acts as small cutting edges resulting in poor surface finish
The pits and valleys formed due to the smearing and removal of graphite particles from the surface of the workpiece generates voids on the surface of the component leads to higher surface roughness values
Summary
Composite materials exhibits better properties compared to conventional alloys in various applications as they have high specific strength, stiffness and better wear resistance, metal matrix composites are one among them. Pramanik et al.[2], Basavarajappa[3] and Chou and Liu[4] were reported that the main concern when machining of particulate metal matrix composites is extremely high tool wear and poor surface finish due to the abrasive action of the ceramic reinforcing particles compared to monolithic alloys. This is due to the presence of hard ceramic particles in composites, which acts as small cutting edges resulting in poor surface finish. This study presents the results of a detailed experimental investigation to determine the effect of cutting parameters and tool material on surface roughness and chip formation on turning of Al2219/15SiCp and Al2219/15SiCp-3Gr composites
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