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Study on Machining Parameters for Thrust Force and Torque in Milling AA7039 Composites Reinforced with Al2O3/B4C/SiC Particles

Year 2016, Volume: 2 Issue: 2, 68 - 75, 22.06.2016
https://doi.org/10.19072/ijet.05966

Abstract

Metal matrix composites are used in many industrial fields such as automobile, military and aerospace applications due to their superior mechanical properties. In the present study, three aluminum 7039 metal matrix composite (MMCs) samples reinforced with 10 wt.% particulates of aluminum oxide (Al2O3), 10 wt.% boron carbide (B4C), and 10 wt.% silicon carbide (SiC) were successfully fabricated using a powder metallurgy and hot extrusion method. The influences of cutting parameters on the thrust cutting force and torque during milling of the three MMCs were investigated under dry machining conditions. The milling tests were performed based on the Taguchi orthogonal -array design of experiments, for different machining parameters such as cutting speed, feed and depth of cut. The effect of reinforcement contents on cutting force and torque were specified by utilizing analysis of variance (ANOVA). Mathematical models have been generated for the thrust force and torque through regression method. The results indicated that the minimal thrust force and torque were obtained in the machining of the Al2O3 reinforced specimen. The cutting force was directly influenced by the cutting feed and the axial cutting depth was the most effective machining parameter affecting milling torque in the machining of three composite specimens. The experimental results were modeled using regression analysis and artificial neural networks (ANN) to predict the thrust force and torque. The thrust force and torque were predicted with a mean squared error equal to 5.85% and 5.12% respectively using ANN models.

References

  • Ş. Karabulut, U. Gökmen and H. Çinici, “Study on the mechanical and drilling properties of AA7039 composites reinforced with Al2O3/B4C/SiC particles”, Compos. Part. B, vol. 93, pp. 43-55, May 2016.
  • K. Umanath, K. Palanikumar and ST. Selvamani, “Composites: Part B Analysis of dry sliding wear behaviour of Al6061/SiC/Al2O3 hybrid metal matrix composites”, Compos Part B, vol. 53, pp. 159–68, October 2013.
  • Ş. Karabulut, “Optimization of surface roughness and cutting force during AA7039/ Al2O3 metal matrix composites milling using neural networks and Taguchi method” Measurement, vol. 66, pp. 139-149, April 2015.
  • E. Budak, “Analytical models for high performance milling. Part I: Cutting forces, structural deformations and tolerance integrity”, Int. J. Mach. Tools Manuf, vol. 46, no. 12, pp. 1478-1488, October 2006.
  • H. Saglam, S. Yaldiz and F. Unsacar, “The effect of tool geometry and cutting speed on main cutting force and tool tip temperature”, Mater. Des., vol. 28, no. 1, pp. 101-111, 2007.
  • M.E. Merchant, “Basic mechanics of the metal cutting process”, ASME J. Appl. Mech, vol. 66, pp. 168–175, 1944.
  • E.H. Lee and B.W. Shaffer, “The theory of plasticity applied to a problem of machining”, ASME Trans. J. Appl. Mech., vol. 18, pp. 405–413, 1951.
  • S. Kannan, H.A. Kishawy and I. Deiab, “Cutting forces and TEM analysis of the generated surface during machining metal matrix composites”, J. Mater. Process. Technol, vol. 209, no. 5, pp. 2260-2269, 2009.
  • Y. Ozcatalbas, “Investigation of the machinability behaviour of Al4C3 reinforced Al-based composite produced by mechanical alloying technique”, Compos. Sci. Technol., vol. 63, no. 1, pp. 53-61, 2003.
  • K. Palanikumar and A. Muniaraj, “Experimental investigation and analysis of thrust force in drilling cast hybrid metal matrix (Al–15%SiC–4%graphite) composites”, Measurement, vol. 53, pp. 240–250, 2014.
  • J.T. Lin, D. Bhattacharyya and C. Lane, “Machinability of a silicon carbide reinforced aluminium metal matrix composite”, Wear, vol. 181, pp. 883–888, 1995.
  • A. Manna, B. Bhattacharayya, “A study on machinability of Al=SiC-MMC” J. Mater. Process. Technol, vol. 140, no. 1, pp. 711–716, 2003.
  • M. El-Gallab and M. Sklad, “Machining of Al/SiC particulate metal matrix composites: part II: workpiece surface integrity”, J. Mater. Process. Technol, vol. 83, no. 1, pp. 277–285, 1998.
  • Ş. Karabulut, H. Çinici and H. Karakoç, “Experimental Investigation and Optimization of Cutting Force and Tool Wear in Milling Al7075 and Open-Cell SiC Foam Composite”, AJSE–Engineering., vol. 41, pp. 1797-1812, 2016.
  • B. Das, S. Roy, R.N. Rai and S.C. Saha, “Study on machinability of in situ Al–4.5%Cu–TiC metal matrix composite-surface finish, cutting force prediction using ANN”, CIRP J. Manuf. Sci. Technol., vol 12, pp. 67–78, 2016.
  • Ş. Karabulut, A. Güllü, “Farklı yanaşma açıları ile vermiküler grafitli dökme demirin frezelenmesinde kesme kuvvetlerinin araştırılması ve analitik modellenmesi”, Gazi Üniv. Müh. Mim. Fak. Der., vol. 28 1, pp. 135-143, 2013.
  • V. Hiremath, P. Badiger, V. Auradi, S.T. Dundur and S.A. Kori, “Influence of particle size on Cutting Forces and Surface Roughness in Machining of B4Cp-6061 Aluminium Matrix Composites”, In IOP Conference Series: Materials Science and Engineering, vol. 114, pp. 012041, February 2016.
  • M.T. Hayajneh, A.M. Hassan and A.T. Mayyas, “Artificial neural network modeling of the drilling process of self-lubricated aluminum/alumina/graphite hybrid composites synthesized by powder metallurgy technique”, J. Alloys Compd., vol. 478, no. 1, pp. 559-565, 2009.
Year 2016, Volume: 2 Issue: 2, 68 - 75, 22.06.2016
https://doi.org/10.19072/ijet.05966

Abstract

References

  • Ş. Karabulut, U. Gökmen and H. Çinici, “Study on the mechanical and drilling properties of AA7039 composites reinforced with Al2O3/B4C/SiC particles”, Compos. Part. B, vol. 93, pp. 43-55, May 2016.
  • K. Umanath, K. Palanikumar and ST. Selvamani, “Composites: Part B Analysis of dry sliding wear behaviour of Al6061/SiC/Al2O3 hybrid metal matrix composites”, Compos Part B, vol. 53, pp. 159–68, October 2013.
  • Ş. Karabulut, “Optimization of surface roughness and cutting force during AA7039/ Al2O3 metal matrix composites milling using neural networks and Taguchi method” Measurement, vol. 66, pp. 139-149, April 2015.
  • E. Budak, “Analytical models for high performance milling. Part I: Cutting forces, structural deformations and tolerance integrity”, Int. J. Mach. Tools Manuf, vol. 46, no. 12, pp. 1478-1488, October 2006.
  • H. Saglam, S. Yaldiz and F. Unsacar, “The effect of tool geometry and cutting speed on main cutting force and tool tip temperature”, Mater. Des., vol. 28, no. 1, pp. 101-111, 2007.
  • M.E. Merchant, “Basic mechanics of the metal cutting process”, ASME J. Appl. Mech, vol. 66, pp. 168–175, 1944.
  • E.H. Lee and B.W. Shaffer, “The theory of plasticity applied to a problem of machining”, ASME Trans. J. Appl. Mech., vol. 18, pp. 405–413, 1951.
  • S. Kannan, H.A. Kishawy and I. Deiab, “Cutting forces and TEM analysis of the generated surface during machining metal matrix composites”, J. Mater. Process. Technol, vol. 209, no. 5, pp. 2260-2269, 2009.
  • Y. Ozcatalbas, “Investigation of the machinability behaviour of Al4C3 reinforced Al-based composite produced by mechanical alloying technique”, Compos. Sci. Technol., vol. 63, no. 1, pp. 53-61, 2003.
  • K. Palanikumar and A. Muniaraj, “Experimental investigation and analysis of thrust force in drilling cast hybrid metal matrix (Al–15%SiC–4%graphite) composites”, Measurement, vol. 53, pp. 240–250, 2014.
  • J.T. Lin, D. Bhattacharyya and C. Lane, “Machinability of a silicon carbide reinforced aluminium metal matrix composite”, Wear, vol. 181, pp. 883–888, 1995.
  • A. Manna, B. Bhattacharayya, “A study on machinability of Al=SiC-MMC” J. Mater. Process. Technol, vol. 140, no. 1, pp. 711–716, 2003.
  • M. El-Gallab and M. Sklad, “Machining of Al/SiC particulate metal matrix composites: part II: workpiece surface integrity”, J. Mater. Process. Technol, vol. 83, no. 1, pp. 277–285, 1998.
  • Ş. Karabulut, H. Çinici and H. Karakoç, “Experimental Investigation and Optimization of Cutting Force and Tool Wear in Milling Al7075 and Open-Cell SiC Foam Composite”, AJSE–Engineering., vol. 41, pp. 1797-1812, 2016.
  • B. Das, S. Roy, R.N. Rai and S.C. Saha, “Study on machinability of in situ Al–4.5%Cu–TiC metal matrix composite-surface finish, cutting force prediction using ANN”, CIRP J. Manuf. Sci. Technol., vol 12, pp. 67–78, 2016.
  • Ş. Karabulut, A. Güllü, “Farklı yanaşma açıları ile vermiküler grafitli dökme demirin frezelenmesinde kesme kuvvetlerinin araştırılması ve analitik modellenmesi”, Gazi Üniv. Müh. Mim. Fak. Der., vol. 28 1, pp. 135-143, 2013.
  • V. Hiremath, P. Badiger, V. Auradi, S.T. Dundur and S.A. Kori, “Influence of particle size on Cutting Forces and Surface Roughness in Machining of B4Cp-6061 Aluminium Matrix Composites”, In IOP Conference Series: Materials Science and Engineering, vol. 114, pp. 012041, February 2016.
  • M.T. Hayajneh, A.M. Hassan and A.T. Mayyas, “Artificial neural network modeling of the drilling process of self-lubricated aluminum/alumina/graphite hybrid composites synthesized by powder metallurgy technique”, J. Alloys Compd., vol. 478, no. 1, pp. 559-565, 2009.
There are 18 citations in total.

Details

Journal Section Articles
Authors

Sener Karabulut

Publication Date June 22, 2016
Published in Issue Year 2016 Volume: 2 Issue: 2

Cite

APA Karabulut, S. (2016). Study on Machining Parameters for Thrust Force and Torque in Milling AA7039 Composites Reinforced with Al2O3/B4C/SiC Particles. International Journal of Engineering Technologies IJET, 2(2), 68-75. https://doi.org/10.19072/ijet.05966
AMA Karabulut S. Study on Machining Parameters for Thrust Force and Torque in Milling AA7039 Composites Reinforced with Al2O3/B4C/SiC Particles. IJET. June 2016;2(2):68-75. doi:10.19072/ijet.05966
Chicago Karabulut, Sener. “Study on Machining Parameters for Thrust Force and Torque in Milling AA7039 Composites Reinforced With Al2O3/B4C/SiC Particles”. International Journal of Engineering Technologies IJET 2, no. 2 (June 2016): 68-75. https://doi.org/10.19072/ijet.05966.
EndNote Karabulut S (June 1, 2016) Study on Machining Parameters for Thrust Force and Torque in Milling AA7039 Composites Reinforced with Al2O3/B4C/SiC Particles. International Journal of Engineering Technologies IJET 2 2 68–75.
IEEE S. Karabulut, “Study on Machining Parameters for Thrust Force and Torque in Milling AA7039 Composites Reinforced with Al2O3/B4C/SiC Particles”, IJET, vol. 2, no. 2, pp. 68–75, 2016, doi: 10.19072/ijet.05966.
ISNAD Karabulut, Sener. “Study on Machining Parameters for Thrust Force and Torque in Milling AA7039 Composites Reinforced With Al2O3/B4C/SiC Particles”. International Journal of Engineering Technologies IJET 2/2 (June 2016), 68-75. https://doi.org/10.19072/ijet.05966.
JAMA Karabulut S. Study on Machining Parameters for Thrust Force and Torque in Milling AA7039 Composites Reinforced with Al2O3/B4C/SiC Particles. IJET. 2016;2:68–75.
MLA Karabulut, Sener. “Study on Machining Parameters for Thrust Force and Torque in Milling AA7039 Composites Reinforced With Al2O3/B4C/SiC Particles”. International Journal of Engineering Technologies IJET, vol. 2, no. 2, 2016, pp. 68-75, doi:10.19072/ijet.05966.
Vancouver Karabulut S. Study on Machining Parameters for Thrust Force and Torque in Milling AA7039 Composites Reinforced with Al2O3/B4C/SiC Particles. IJET. 2016;2(2):68-75.

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