Study of tool wear and surface roughness in machining of homogenised

SiC-p reinforced aluminium metal matrix composite

Krishnakumar R, Deppakpraveenraj, Divakar K

Abstract

Metal matrix composites (MMC) have become a large leading material in composite materials and particle reinforced aluminium M MCs have
received considerable attention due to their excellent engineering properties. These materials are known as the difficult-to-machine materials,
because of the hardness and abrasive nature of reinforcement element like silicon carbide (SiC) particles. In this study, hom ogenised 5%
SiC-p aluminium MMC material was selected for experimental investigation of tool wear and surface roughness. Two types of K10 cutting
tool (uncoated and TiN-coated) were used at different cutting speeds (50, 100 and 150 m/min), feed rates (0.1, 0.2 and 0.3 mm/rev) and depths
of cut (0.5, 1 and 1.5 mm). In dry turning condition, tool wear was mainly affected by cutting speed, increased with increasing cutting speed.
Tool wear was lower when coated cutting tool was used in comparison to uncoated one. Surface roughness influenced with cutting speed and
feed rate. Higher cutting speeds and lower feed rates produced better surface quality.
© 2005 Elsevier B.V. All rights reserved.

Keywords: Metal matrix composites; Machining; Tool wear; Surface roughness

1. Introduction The main problem, in case of 5% SiC-p Al-MMC ma-

chining, is that it is known as the difficult-to-machine mate-
Composite materials are named as the ‘materials of the rial, because of the existence of hard abrasive reinforcement
future’ in 1970s when they have been introduced in engi- particles are harder than cutting tool worn rapidly during
neering applications [1]. Metal matrix composites (MMC) machining of these materials: the main tool wear mecha-
are widely used composite materials in aerospace, automo- nism in the machining of this type material is abrasion on
tive, electronics and medical industries. They have outstand- the flank face. There has been no proof of chemical wear
ing properties like high strength, low weight, high modules, [4].
low ductility, high wear resistance, high thermal conductiv- There have been number of studies in machining of SiC-p
ity and low thermal expansion. These desired properties are Al-MMC, but based on the machining 5% SiC-p Al-MMC,
mainly manipulated by the matrix, the reinforcement element few studies were conducted. Li and Seah [5] investigated
and the interface [1,2]. machining properties of 5% SiC-p Al-MMC material using
As the matrix element, aluminium, titanium and magne- coated carbide cutting tool in turning operation. They applied
sium alloy are used, while the popular reinforcements are sil- various cutting speed (maximum was 88 m/min) and con-
icon carbide (SiC) and alumina (Al2O3). Aluminium-based cluded that increasing cutting speed raised tool wear. They
SiC particle reinforced MMC materials have become use- also noticed abrasion wear on flank face of the tool.
ful engineering materials due to their properties such as low Kılıçkap et al. [6] examined the same material in turn-
weight, heat-resistant, wear-resistant and low cost [3]. ing. They concluded that the built-up edge formation oc-
curred at low cutting speed and this provided lower cutting
tool wear. Tool wear increased with increasing cutting speed.
They also noticed abrasion type wear mechanism. Cutting
speed seemed the most influential machining parameter on
tool life and surface quality. Coating provided better results Table 2
like longer tool life and better surface finish. Selected machining conditions
The other study was carried out by Lin et al. The effects Cutting tool Uncoated and TiN-coated K10
of material properties on tool wear and surface roughness in Cutting speed (m/min) 50, 100 and 150
machining of 5% SiC-p Al-MMC examined. The effect of Feed rate (mm/rev) 0.1, 0.2 and 0.3
heat-treated and type of heat treatments of the material were Depth of cut (mm) 0.5, 1 and 1.5
Cutting medium Dry
decreased tool life and increased surface roughness [7]. Cutting period (s) 90
In summary, early studies provided limited information on
the effects of machining parameters on tool wear and surface
roughness for 5% SiC-p Al-MMC. The most influential ma- Average flank wear (VB) was taken as tool wear criteria
chining parameter on tool wear and surface roughness was and the measurements of it were conducted by using Nikon
cutting speed. The feed rate was also effective on surface Epiphot 200 optical microscope. For surface roughness mea-
roughness. The heat treatment was negatively affecting tool surements, Taylor-Hobson Surtronic 3+ equipment was used.
wear and surface finish. The measurements of tool wear and surface roughness (Ra)
The present experimental study aimed to examine the se- were carried out at regular intervals during 90 s machining
lected machining parameters on tool wear and surface rough- period. Each experiment repeated three times and three mea-
ness in the machining of homogenised 5% SiC-p Al-MMC surements of tool wear and surface roughness were taken
material. The influences of cutting speed, feed rate, depth of from each experiment and the averages of tool wear and sur-
cut, uncoated and coated cutting tool were determined on tool face roughness were obtained.
wear and surface finish. The selected cutting tool was K10
grade. The turning process carried out as dry machining.
3. Results and discussion

2. Experimental The influence of selected cutting speeds on tool wear was

determined. Fig. 1a–c shows the results of tool wear in various
The selected experimental material was manufactured by cutting speeds. It was observed that increasing cutting speed
squeeze casting process. As the matrix materials 99.9% pure produced a faster tool wear. When cutting speed increased
aluminium was used, while 5 wt.% SiC particles with an aver- from 50 to 150 m/min, tool wear value doubled. This is similar
age size of 24 µm were applied as the reinforcement element. to machining any material that the cutting tool worn faster
The specimens were in bar shapes of 90 mm diameter and with using higher cutting speed.
150 mm length. The chemical composition of specimen was The effect of coating on tool produced better tool wear
given in Table 1. This material later homogenised at 550 ◦C results (Fig. 1a–c). In all cutting speed values, TiN-coated
for 5 h and than soaked in the water until cooled down. After K10 grade tool provided a lower tool wear in comparison to
homogenisation process, the hardness of material was 86 HB, uncoated one. The coating of cutting tool helped in reducing
which was 87 HB before. wear on the flank face. This is because of coating cutting tool
Turning method as machining process was selected. The that made tool surface harder than normal surface.
experimental study carried out in MKE brand lathe machine The effect of feed was examined. At low cutting speed,
(6.5 kW power). The selected cutting tool was titanium car- the effect of feed on tool wear was very little; tool wear was
bide K10 grade (ISO code), which was generally recom- slightly higher when higher feeds were used. The influence
mended for machining of MMC materials. The ISO codes of feed was obvious at higher cutting speed, higher feed in-
of cutting tool and tool holder were TNMA 160408 and PT- creased tool wear (Fig. 2a–c). The effect of coating on tool
GNR/L 2525 M16, respectively. The selected machining pa- provided positive result like the effect of cutting speed on
rameters were given in Table 2. The machining process was tool wear, uncoated cutting tool worn faster.
conducted as dry and completed after 90 s turning period. The effect of depth of cut on tool wear was given in
Fig. 3a–c. It was noticed that increase in depth of cut slightly
Table 1 increased tool wear and similar trends observed at all ma-
Chemical composition of experimental material (%) chining conditions.
Si 7 The examination of machined surface quality was con-
Mg 2 ducted at the selected machining conditions. It was noticed
Fe 0.54 that the cutting speed and feed rate were the influential ma-
Mn 0.38
Zn 0.11
chining parameters on the surface roughness. The effect of
Ni 0.074 depth of cut was little.
Co 0.116 The influence of cutting speed on surface roughness was
Cu 0.13 given in Fig. 4a–c. The use of low cutting speed produced a
Ti 0.086 better surface finish in all machining conditions. It was no-
Al Balanced
ticed that the coating played important role on surface qual-
Fig. 1. The effect of cutting speed on tool wear. Fig. 2. The influence of feed rate on tool wear.
Fig. 3. The effect of depth of cut on tool wear.

Fig. 4. The effect of cutting speed on surface roughness.

Fig. 5. The effect of feed rates on surface roughness. Fig. 6. The effects of depth of cut on surface roughness.
ity; the coated cutting tool provided a lower surface rough- g. Feed rate was an effective machining parameter on sur-
ness. The minimum surface roughness value was 3 µm when face roughness. Higher feed rates produced poor surface
0.1 mm/rev feed rate at any depth of cut. For this machining quality.
condition, the surface roughness trend was almost straight. h. The effect of depth of etch was very little, even not influ-
The experimental results of feed rates effect on surface ential.
roughness were shown in Fig. 5a–c. The surface roughness i. TiN-coated cutting tool provided better results; it de-
increased with using higher feed rates in all machining con- creased tool wear and provided smoother surface finish.
ditions. This was attributed to high temperature in the cut- j. The influence of heat treatment of this material like ho-
ting zone. Higher feed values increases temperature and this mogenised process affected badly, it increased tool wear
cause to decrease bonding effect between SiC-p and Al- and surface roughness compared to not heat treatment ap-
matrix. Aluminium softens and SiC particles are broken [8]. plication of the material.
It was observed that the effect of coating was clear; provided
As a result, the recommended machining conditions for
lower surface roughness. The influence of feed rate on surface
homogenised 5% SiC-p Al-MMC material would be the se-
roughness affected with cutting speed, but the application of
lection of low cutting speed with high feed rate and depth
the highest cutting speed with the fastest feed rate provided
of cut for rough and medium turning process with coated
little change. However, the trend was similar.
carbide cutting tool to obtain longer tool life, and high cut-
The influences of depths of cut on surface finish were in-
ting speed with low feed rate at any depth of cut with coated
vestigated and the results were given in Fig. 6a–c. It was
cutting tool for finish machining to produce better surface
noticed that depth of cut was the least influential machin-
finish.
ing parameter on surface roughness. The surface roughness
trends were nearly straight line. However, the coated cutting
tool performed positively; surface quality increased with us-
Acknowledgements
ing coated cutting tool. The best surface roughness value was
3 µm with coated cutting tool with the highest cutting speed
The authors would like to thank Dr. Ali Kalkanli (Middle
in all feed rates and depths of cut.
East Technical University, Ankara, Turkey) for preparation
of specimens and Mr. Tahsin Alsan (Böhler Hard Metal and
Tool Com., Istanbul, Turkey) for providing cutting tools.
4. Conclusion

The tool wear and surface roughness results of the exper-

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