Title: Machining of metal matrix composites: influence of B4C ceramic particulate addition on cutting forces and surface roughness of 6061Al alloy

Authors: Vijaykumar Hiremath; Virupaxi Auradi; Suresh T. Dundur

Addresses: Department of Mechanical Engineering, Siddaganga Institute of Technology, Tumkur – 572 103, Karnataka, India ' Department of Mechanical Engineering, Siddaganga Institute of Technology, Tumkur – 572 103, Karnataka, India ' Department of Industrial and Production Engineering, Basaveshwar Engineering College, Bagalkot – 587 102, Karnataka, India

Abstract: Amongst advanced materials, metal matrix composites (MMCs) are gaining importance as materials for structural applications. In particular, particulate reinforced aluminium MMCs have received considerable attention due to their superior properties such as high strength to weight ratio, excellent low-temperature performance, high wear resistance, and high thermal conductivity. The present work aims at experimental investigations on the influence of addition of ceramic particles (B4C particulate) on the machining of 6061Al matrix produced by stir casting method. Cutting forces and surface roughness were evaluated before and after addition of B4C particles to 6061Al matrix. Results suggest that machining forces decreased with increase in cutting speed in both unreinforced and reinforced alloys. However, a drastic decrease in thrust force was noticed at a cutting speed of 43 m/min. The values of cutting forces obtained were high while dry machining at higher feed rate and depth of cut. Results of surface roughness measurements reveal that the higher surface finish is obtained at higher cutting speeds in both cases. Further, the surface roughness increased with increase in feed rate and depth of cut. The role of the reinforcement particles is revealed by the experimental results thus providing a guide for better control of the machining process.

Keywords: metal matrix composites; MMCs; B4C ceramic particles; cutting forces; surface roughness; machinability; MMC machining; surface quality; aluminium alloys; particulate reinforcement; stir casting; thrust force; cutting speed; cutting forces; dry machining; feed rate; depth of cut; surface finish.

DOI: 10.1504/IJMMM.2016.077710

International Journal of Machining and Machinability of Materials, 2016 Vol.18 No.4, pp.365 - 376

Received: 07 Apr 2015
Accepted: 21 Sep 2015

Published online: 13 Jul 2016 *

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