Tool wear and chip formation analysis of aluminium hybrid metal matrix composite

Abstract

Since last two decades technology has changed rapidly in each industry from consumer goods to aerospace. To quench the thrust of technology advancement of industries, the research community has to develop novel materials. As a part of the ongoing process of material development and machinability study, present work carried out to find out the effect of reinforcement and machining parameter variation on the cutting tool. Furthermore, chip analysis was carried out to find out the effect of reinforcement and cutting parameter variation on types of chip formed. The desirability of the chips was decided based on the surface finish value. Pure aluminium was used as a matrix material while; B4C, Mg, Ti and Graphite were used as reinforcement. It was observed that the unfavourable machining parameter reduces tool life considerably and this phenomenon was more evident in the carbide coated insert compared to PCD insert. High tool wear was observed during machining of composite material compared to the aluminium matrix. An undesired chip produced when feed increases and speed reduces. Moreover, change in reinforcement amount also has an effect on the types of chip produces. The surface roughness value up to 0.50 μm was reduced by a combination of optimized cutting parameters and change in reinforcement amount.