Machining of metal matrix composites: influence of B4C ceramic particulate addition on cutting forces and surface roughness of 6061Al alloy

Abstract

Amongst advanced materials, metal matrix composites (MMCs) are gaining importance as materials for structural applications. In particular, particulate reinforced aluminium MMCs have received considerable attention due to their superior properties such as high strength to weight ratio, excellent low-temperature performance, high wear resistance, and high thermal conductivity. The present work aims at experimental investigations on the influence of addition of ceramic particles (B4C particulate) on the machining of 6061Al matrix produced by stir casting method. Cutting forces and surface roughness were evaluated before and after addition of B4C particles to 6061Al matrix. Results suggest that machining forces decreased with increase in cutting speed in both unreinforced and reinforced alloys. However, a drastic decrease in thrust force was noticed at a cutting speed of 43 m/min. The values of cutting forces obtained were high while dry machining at higher feed rate and depth of cut. Results of surface roughness measurements reveal that the higher surface finish is obtained at higher cutting speeds in both cases. Further, the surface roughness increased with increase in feed rate and depth of cut. The role of the reinforcement particles is revealed by the experimental results thus providing a guide for better control of the machining process.