Effect of type and percentage of reinforcement for optimization of the cutting force in turning of Aluminium matrix nanocomposites using response surface methodologies

Aluminium matrix composites (AMCs) now hold a significant share of raw materials in many applications. It is of prime importance to study the machinability of such composites so as to enhance their applicability. Sufficient work has been done for studying the machining of AMCs with particle reinforcements of micron range. This paper presents the study of AMCs with particle reinforcement of under micron range i.e. nanoparticles. This paper brings out the results of an experimental investigation of type and weight percent of nanoparticles on the tangential cutting force during turning operation. SiC, Gr and SiC-Gr (in equal proportions) were used with Al-6061 alloy as the matrix phase. The results indicate that composites with SiC require greater cutting force followed by hybrid and then Gr. Increase in the weight percent also significantly affected the magnitude of cutting force. RSM was used first to design and analyze the experiments and then to optimize the turning process and obtain optimal conditions of weight and type of reinforcements for turning operation.

[1]  M. Davidson,et al.  Surface roughness prediction of flow-formed AA6061 alloy by design of experiments , 2008 .

[2]  F. O. Rasch,et al.  Machinability of Particulate Aluminium Matrix Composites , 1992 .

[3]  M. Guo,et al.  Tribological behavior of self-lubricating aluminium/SiC/graphite hybrid composites synthesized by the semi-solid powder-densification method , 2000 .

[4]  Devinder Priyadarshi,et al.  Optimization for Turning of Al-6061-SiC-Gr Hybrid Nanocomposites Using Response Surface Methodologies , 2016 .

[5]  T. Senthilvelan,et al.  Optimization of machining parameters for EDM operations based on central composite design and desirability approach , 2014 .

[6]  B. K. Lambert,et al.  Mathematical models to predict surface finish in fine turning of steel. Part I. , 1981 .

[7]  Guoqun Zhao,et al.  Optimal Design of Second-Step Welding Chamber for a Condenser Tube Extrusion Die Based on the Response Surface Method and the Genetic Algorithm , 2013 .

[8]  B. Sridhara,et al.  Wear characteristics of hybrid aluminium matrix composites reinforced with graphite and silicon carbide particulates , 2010 .

[9]  D. Abdul Budan,et al.  Comparative Study on the Machinability Aspects of Aluminium Silicon Carbide and Aluminium Graphite Composites , 2007 .

[10]  P. Sreejith,et al.  Dry machining: Machining of the future , 2000 .

[11]  Anil Mital,et al.  Surface finish prediction models for fine turning , 1988 .

[12]  Kali Dass,et al.  Optimization of Machining Parameters in Turning of Titanium (Grade-5) Alloy Using Response Surface Methodology , 2012 .

[13]  T. Senthilvelan,et al.  Application of response surface method on machining of Al–SiC nano-composites , 2013 .

[14]  L. Krishnamurthy.  Machinability studies on metal matrix hybrid composites , 2008 .

[15]  Pradeep K. Rohatgi,et al.  Metal Matrix Composites , 2020, Composite Materials.

[16]  M. E. Merchant.  AN INTERPRETIVE LOOK AT 20TH CENTURY RESEARCH ON MODELING OF MACHINING , 1998 .

[17]  M. Surappa,et al.  The machinability of a cast aluminium alloy-graphite particle composite , 1988 .

[18]  N. Muthukrishnan,et al.  Investigation on Surface Roughness in Abrasive Water-Jet Machining by the Response Surface Method , 2014 .

[19]  R. Subramanian,et al.  Influence of graphite and machining parameters on the surface roughness of Al-fly ash/graphite hybrid composite: a Taguchi approach , 2013 .

[20]  P. S. Satsangi,et al.  Multiple-response optimization of turning machining by the taguchi method and the utility concept using uni-directional glass fiber-reinforced plastic composite and carbide (k10) cutting tool , 2013 .

[21]  R. H. Myers,et al.  Response Surface Methodology: Process and Product Optimization Using Designed Experiments , 1995 .

[22]  J. Davim,et al.  Drilling of hybrid aluminium matrix composites , 2008 .

[23]  Farghalli A. Mohamed,et al.  Particulate reinforced metal matrix composites — a review , 1991, Journal of Materials Science.

[24]  P. Hariharan,et al.  Optimization of Micro-WEDM Process of Aluminum Matrix Composite (A413-B4C): A Response Surface Approach , 2013 .

[25]  A. Mahadevan,et al.  Influence of sliding speed on the dry sliding wear behaviour and the subsurface deformation on hybrid metal matrix composite , 2007 .

[26]  V. C. Venkatesh,et al.  Application of response surface methodology in describing the performance of coated carbide tools when turning AISI 1045 steel , 2004 .

[27]  S. Jacobson,et al.  Tool wear mechanisms in intermittent cutting of metal matrix composites , 1994 .