Abstract
The role played by hollow ceramic thin-walled aluminium oxide microballoons on the shear deformation characteristics of AZ31 Magnesium syntactic foam is studied through high-speed machining. The ceramic microballoons embedded in the AZ31 matrix provides the necessary stiffness for these novel foams. The effect of hollow ceramic microballoon properties, such as the volume fraction, thin wall thickness to diameter ratio, and microballoon diameter, profoundly affects the chip formation. A novel force model has been proposed to explain the causes of variation in cutting forces during chip formation. The results showed an increase in machining forces during cutting AZ31 foams dispersed with higher volume fraction and finer microballoons. At a lower (Davg/h) ratio, the mode of microballoon deformation was a combination of bubble burst and fracture through an effective load transfer mechanism with the plastic AZ31 Mg matrix. The developed force model explained the key role played by AZ31 matrix/alumina microballoon on tool surface friction and showed a better agreement with measured machining forces.
Highlights
Metal matrix closed cell syntactic foams comprise of hollow alumina ceramic micro balloons dispersed into the AZ31 Magnesium (Mg) matrix through the squeeze casting method
Effect of process parameters on the variations in cutting forces during machining AZ31 magnesium foam reinforced with a 15% volume of alumina hollow bubbles
A constitutive force model for the machining of AZ31 magnesium syntactic foams reinforced with ceramic alumina micro balloons is presented
Summary
Metal matrix closed cell syntactic foams comprise of hollow alumina ceramic micro balloons dispersed into the AZ31 Magnesium (Mg) matrix through the squeeze casting method. These requirements necessitated the interest to study the machinability characteristics of magnesium syntactic foams which are a relatively new class of materials to be shaped into useful technological products at lower manufacturing cost. Many studies have addressed the primary processing methods for metal syntactic foams such as casting [6,7,8]. Characterizations of their mechanical behavior upon impact or loading with various matrix and sphere materials have been carried out [9,10,11,12]. Several machining studies on porous cellular structures have been carried out
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