0
TECHNICAL PAPERS

Flank Wear Progression During Machining Metal Matrix Composites

[+] Author and Article Information
S. Kannan, H. A. Kishawy

Department of Mechanical Engineering, University of New Brunswick, Fredericton, NB E3B 5A3, Canada

M. Balazinski

Department of Mechanical Engineering, Ecole Polytechnique de Montréal, Québec, Canada

J. Manuf. Sci. Eng 128(3), 787-791 (Nov 28, 2005) (5 pages) doi:10.1115/1.2164508 History: Received July 20, 2005; Revised November 28, 2005

The machining of composites present a significant challenge to the industry. The abrasive reinforcements cause rapid tool wear and increases the machining cost. The results from machining metal matrix composites (MMCs) with conventional tools show that the main mechanism of tool wear includes two-body abrasion and three-body abrasion. A more flexible method that can be considered as a cost-saving technique is therefore sought for studying the machinability characteristics of these materials. In the previous paper, a methodology for predicting the tool flank wear progression during bar turning of MMCs was presented (Kishawy, Kannan, and Balazinski, Ann. CIRP, 54/1, pp. 55–59). In the proposed model, the wear volume due to two-body and three-body abrasion mechanisms was formulated. Then, the flank wear rate was quantified by considering the tool geometry in three-dimensional (3D) turning. Our main objective in this paper is to validate the proposed model by conducting extensive bar turning experiments under a wide range of cutting conditions, tool geometries, and composite material compositions. The cutting test results showed good agreement between predicted and measured tool wear progression.

Copyright © 2006 by American Society of Mechanical Engineers
Your Session has timed out. Please sign back in to continue.

References

Figures

Grahic Jump Location
Figure 1

Wear progression during cutting 6061 alumina MMC reinforced with different volume fractions (condition 2)

Grahic Jump Location
Figure 2

A comparison of wear progression during cutting 6061 MMC with a different volume fraction of alumina particulates under condition 2; cutting time: 1000s

Grahic Jump Location
Figure 3

Wear progression during cutting 6061 MMC reinforced with different particle size (under condition 1)

Grahic Jump Location
Figure 15

Tool wear progression during cutting A356 MMC under Condition 6

Grahic Jump Location
Figure 14

A comparison of tool wear progression during cutting A356 MMC at different feed rates under condition 5; cutting time: 15s

Grahic Jump Location
Figure 13

Tool wear progression during cutting A356 MMC under condition 5

Grahic Jump Location
Figure 12

SEM and optical micrographs of cutting tool flank wear surface tested at different cutting speeds (condition 4); (a) 90m∕min; (b) 185m∕min

Grahic Jump Location
Figure 11

A comparison of wear progression during cutting A356 MMC at different cutting speeds under Condition 4, cutting time: 4.6s

Grahic Jump Location
Figure 10

Wear progression during cutting A356 MMC under condition 4

Grahic Jump Location
Figure 9

Images of cutting tool flank wear surface of different nose radii tools (condition 3); (a) R=0.4mm, (b) R=0.8mm

Grahic Jump Location
Figure 8

A comparison of tool wear progression during cutting A356 MMC with different nose radii tools under condition 3; cutting time: 1min

Grahic Jump Location
Figure 7

Tool wear progression during cutting A356 MMC with different tool nose radius under condition 3

Grahic Jump Location
Figure 6

Optical micrographs of cutting tool flank wear surface tested with 6061 MMC with different particle sizes (condition 1). (a) 25μm; (b) 9.5μm.

Grahic Jump Location
Figure 5

Images of cutting tool flank wear surface after machining 6061 MMC with different volume fractions (condition 2). (a) 10 vol%; (b) 20 vol%.

Grahic Jump Location
Figure 4

A comparison of wear progression during cutting 6061 MMC/10% alumina MMC with different particle sizes under condition 1; cutting time: 1750s

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In