Title: Experimental modelling and analysis of drilling (Al2O3)p/6061 metal matrix composites using PCD tool

Authors: M. Ramulu, D. Kim, H. Kao, P.N. Rao

Addresses: Department of Mechanical Engineering, Box 352600, University of Washington, Seattle, WA 98195-2600, USA. ' School of Engineering and Computer Science, Washington State University, Vancouver, WA 98686-9600, USA. ' Department of Mechanical Engineering, Box 352600, University of Washington, Seattle, WA 98195-2600, USA. ' Department of Industrial Technology, University of Northern Iowa, Cedar Falls, IA 50614-0178, USA

Abstract: Metal matrix composites (MMCs) machining is not difficult but presents different machining requirements compared to other materials because of the abrasive characteristics of the reinforced particulates. In order to use these materials for regular production, it is necessary to develop methods by which the machining process can be optimised. The objective of this research was to develop mathematical models to predict drilling forces. Cutting parameters included in the mathematical models are cutting speed, feed rate, and volume fraction of reinforcement. Experiments were conducted by using PCD tools to drill Al2O3 particulate reinforced aluminium-based metal matrix. The Response Surface Methodology (RSM) were used to analyse experimental data and develop semi-empirical models. Semi-empirical drilling force models, which was developed for conventional materials, was modified to suit the drilling of MMCs and was verified with the present experimental study as well as the available data from the literature.

Keywords: drilling force; hole quality; machinability; metal matrix composites; MMCs; mathematical modelling; surface roughness; response surface methodology; RSM; cutting speed; feed rate; aluminium.

DOI: 10.1504/IJMPT.2008.018373

International Journal of Materials and Product Technology, 2008 Vol.32 No.1, pp.20 - 40

Published online: 19 May 2008 *

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