Title: Analysis of two- and three-body abrasive wear during machining of aluminium-based metal matrix composite

Authors: S. Kannan; H.A. Kishawy; M. Balazinski

Addresses: Department of Turbine Blade Facility, Rolls-Royce plc, Derby DE24 8BJ, UK ' Machining Research Laboratory, Faculty of Engineering and Applied Science, University of Ontario Institute of Technology, 2000 Simcoe Street North, Oshawa, Ontario, L1H 7K4, Canada ' Department of Mechanical Engineering, Ecole Polytechnique de Montréal, Montréal, Québec H3C 3A7, Canada

Abstract: Metal matrix composites (MMCs) are new generation engineering materials that possess superior physical and mechanical properties compared to non-reinforced alloys. However, the presence of abrasive ceramic reinforcements in the ductile matrix causes severe tool wear and premature tool failure. Flank wear was found to be the dominant wear mode while the main wear mechanism was abrasion. Analysis of the cutting tools using scanning electron microscopy (SEM) has shown that both two-body and three-body abrasion are operational during machining of MMCs. In this paper, a methodology for predicting the tool flank wear progression during bar turning of MMCs is presented. In the proposed model, the wear volume due to two-body and three-body abrasion mechanisms was formulated. In addition, the flank wear rate was quantified by considering the tool geometry in three dimensional (3D) turning. The main objective of this paper is to investigate the contribution of two-body and three-body abrasion towards the tool wear volume during cutting MMCs.

Keywords: metal matrix composites; MMCs; abrasive wear; MMC machining; aluminium; cutting tools; machining; tool wear; flank wear; bar turning.

DOI: 10.1504/IJMPT.2013.052793

International Journal of Materials and Product Technology, 2013 Vol.46 No.1, pp.81 - 94

Received: 01 Jul 2011
Accepted: 21 Mar 2012

Published online: 19 Mar 2013 *

Full-text access for editors Access for subscribers Purchase this article Comment on this article