Journal of Materials Processing Technology 140 (2003) 711716

A study on machinability of Al/SiC-MMC

A. Manna a, , B. Bhattacharayya b
a Department of Production, Kharagpur Railway Workshop, South Eastern Railway, Kharagpur 721301, India
b Production Engineering Department, Jadavpur University, Kolkata 700032, India

Abstract

The paper presents the result of an experimental investigation on the machinability of silicon carbide particulate aluminium metal matrix
composite during turning using fixed rhombic tools. The influence of machining parameters, e.g. cutting speed, feed and depth of cut on
the cutting force and surface finish criteria were investigated during the experimentation. The combined effect of cutting speed and feed
on the flank wear was investigated during experimentation. The influence of cutting speed, feed rate and depth of cut on the tools wear
and built-up edges (BUEs) were analysed. The BUE and chip formation at different sets of experiments were examined through SEM
micrographs. Test results show that no BUE is formed during machining of Al/SiC-MMC at high speed and low depth of cut. From the
test results and different SEM graphs suitable range of cutting speed, feed and low depth of cut can be selected for proper machining of
Al/SiC-MMC. This practical research analysis and test results on the machinability of Al/SiC-MMC will provide effective guidelines to
the present day manufacturing engineers. The research work findings will also provide useful economic machining solution by utilizing
fixed rhombic tooling during processing of Al/SiC-MMC, which is otherwise usually machined by costly PCD or CBN tools.
2003 Elsevier B.V. All rights reserved.

Keywords: Al/SiC-MMC; Built-up edge; Cutting force; Surface finish

1. Introduction edge and consequently due to friction, high temperature and

Particulate reinforced Al-metal matrix composite
(PRAlMMC) is one of the important composites among
the metal matrix composites, which have SiC particles with
aluminium matrix is harder than tungsten carbide (WC),
which pose many problems in machining. The aluminium
alloy reinforced with discontinuous ceramic reinforcements
is rapidly replacing conventional materials in various au-
tomotive, aerospace and automobile industries [1]. But
Al/SiC-MMCs machining is one of the major problems,
which resist its wide spread engineering application [2].
From some early conventional turning tests on Al/SiC-
MMCs [3,4], it is found that the tool wear is excessive and
surface finish is very poor while carbide tip tools are used
for machining. The hard SiC particles of Al/SiC-MMC,
which intermittently come into contact to the hard surface,
are act as small cutting edges like those of a grinding wheel
on the cutting tool edge which in due course is worn out by
abrasion and resulting in the formation of poor surface fin-
ish during turning [5]. When Al/SiC-MMC job slides over
a hard cutting tool edge during turning it always presents
a newly formed surface to the same portion of the cutting
Corresponding author.
E-mail address: kgpmanna@rediffmail.com (A. Manna).
pressure the particles of the Al/SiC-MMC adhere to the cut-
ting tool edge. In this way more particles will join up with
those already adhering and so-called built-up edge (BUE)
is formed and if this process is continue for some time, it
appears as like as nibbled away on the turned surface and
produces very poor surface finish during turning [6]. Hence,
cost effective machining with generation of good surface
finish on the Al/SiC-MMC jobs during turning operation is
a challenge to the manufacturing engineers in practice.
In view of these above-mentioned machining problems,
main objectives of the paper is to study the influence of
different cutting parameters, e.g. cutting speed, feed rate,
depth of cut on the machinability characteristics, e.g. cut-
ting forces, tool wears, BUE, chip formation and surface
finish during turning of Al/SiC-MMC. The cutting forces,
tool wears, surface finish, BUE and chip formation for dif-
ferent sets of experiments were examined and compared for
searching out the suitable cutting condition through high-
lighting the drawbacks and suggesting proper measures to
be undertaken during machining performance which may
overcome the machining barriers from Al/SiC-MMC. Dur-
ing machining of Al/SiC-MMC, suitability of uncoated car-
bide tool was also investigated for fulfilling various fac-
tors related to machinability. Test results were analysed for
achieving better machining performance during machining
of Al/SiC-MMC.

0924-0136/$ see front matter 2003 Elsevier B.V. All rights reserved.
doi:10.1016/S0924-0136(03)00905-1
712 A. Manna, B. Bhattacharayya / Journal of Materials Processing Technology 140 (2003) 711716

Table 1
250 Feed: 0.5 mm/rev
Specification, specific weight and composition of discontinuous Al/SiC-
Cutting forces (N)

Depth of cut: 0.5 mm

MMC used for experiments 200
150 Px
Specification; density; APS LM6Mg15SiCP ; 2.67 g/cm3 ; 23 m Pz
SiC (%) 15.0 100
Si (%) 12.0 50
Mg (%) 0.5 0
Fe (%) 0.12 20 40 60 100 150 180 225
Cu (%) 0.17 Cutting speed (m/min)
Mn (%) 0.11
Zn (%) 0.10 Fig. 1. Influence of cutting speed on the feed force, Px and cutting
Ti (%) 0.1 force, Pz .
Al Remaining

300
Table 2 Cutting speed: 100 m/min
250
Cutting force (N)

Details of cutting tool used for experimentation Depth of cut:0.5 mm

200
Cutting tool T-Max-U Positive rhombic insert Px
150 Pz
Specification CCGX-09-T3-04-Al-H10
Tool material and grade Uncoated tungsten carbide (WC) (HW-K10) 100
Rake angle ( ) 5 50
Clearance angle ( ) 7
0
Cutting edge angle ( ) 80
Nose radius (mm) 0.4 0.14 0.25 0.33 0.5 0.75 1
Feed rate (mm/rev.)

Fig. 2. Influence the feed rate on feed force, Px and cutting force, Pz .
2. Experimental procedure

Discontinuous particulate reinforced LM6Mg15SiCP Al-
MMC of 80 mm diameter bar is used for experimentation.
Table 1 shows the specification, density, and chemical com-
position with average particle size (APS) of Al/SiC-MMC
used for the experiments. The different sets of experiments
were performed by turning operation on a Combination
Turret Lathe using cutting speed range 20225 m/min,
feed range 0.141.00 mm/rev and depth of cut range
0.251.5 mm. Table 2 shows the details of the cutting tool
used for the experimentation.
The cutting forces (Px and Py ) were measured using
Kistler Piezoelectric Dynamometer of Kistler type 5501 with
a load amplifier of Kistler type 5007 during turning of
Al/SiC-MMC. The BUEs were measured using a Mitutoyo
Shop Microscope with 30 magnification and 1 m resolu-
tion.
3. Test results and discussion
3.1. Cutting forces
operations were performed at constant 0.5 mm/rev feed and
0.5 mm depth of cut. Experimental results represent that
the feed force (Px ) is high at low cutting speed and cutting
force (Pz ) is low at low cutting speed as compared to the
high cutting speed. From the figure, it can be observed that
the cutting force components Px and Pz are decrease by
increasing cutting speed during turning of Al/SiC-MMC.
Fig. 2 shows the influence of feed on the feed force and
cutting force during turning of Al/SiC-MMC. The feed
force (Px ) and cutting force (Pz ) are increased by increas-
ing feed. The feed force and cutting force both are low at
low feed, i.e. 0.14 mm/rev, and both are high at high feed,
i.e. 1.00 mm/rev. Fig. 3 shows the influence of depth of
cut on the feed force and cutting force during turning of
Al/SiC-MMC. The feed force (Px ) and cutting force (Pz )
both increase with increase in depth of cut. The feed force
(Px ) is only 20 N for 0.25 mm depth of cut whereas the feed
force (Px ) is 200 N for 1.5 mm depth of cut. The test results
500
Cutting speed: 100 m/min
Cutting force (N)

400 Feed: 0.5 mm/rev

The measurement of cutting force components is highly 300 Px
essential to analyse more effectively the machinability Pz
200
factors of Al/SiC-MMC. Dry turning operations were per-
100
formed to evaluate the cutting forces. The cutting force
in the direction of the tool travel (Px ) and main cutting 0
force in the direction of cutting velocity vector (Pz ) were 0.25 0.5 0.75 1 1.25 1.5
measured for analysing the machinability characteristics of Depth of cut (mm)
Al/SiC-MMC. Fig. 1 shows the influence of cutting speed Fig. 3. Influence of depth of cut on the feed force, Px and cutting
on the feed force (Px ) and cutting force (Pz ). The turning force, Pz .
 A. Manna, B. Bhattacharayya / Journal of Materials Processing Technology 140 (2003) 711716 713

0.6 Feed : 0.5 mm/rev 0.7 20 m/min

Flank wear, mm

Depth of cut: 0.5 mm 40 m/min

0.4 Length : 50 mm 0.6 60 m/min
100 m/min
Flank wear, mm

0.2 0.5
150 m/min
0.4 180 m/min
0 225 m/min
20 40 60 100 150 180 225 0.3
Cutting speed, m/min 0.2

Fig. 4. Influence of cutting speed (m/min) on flank wear (mm). 0.1

indicate that the cutting force is 120 N for 0.25 mm depth of 0.14 0.25 0.33 0.50 .75 1
cut whereas cutting force is 430 N for 1.5 mm depth of cut. Feed, mm/rev.

Fig. 6. Combined effect of cutting speed and feed rate on flank wear.
3.2. Tool wear

The main wear pattern were observed as regular flank
wear. Flank wear is due to the abrasive action of the re-
inforced particles presence in the metal matrix composite.
The harder particle SiC of hardness 27003500 HV grind the
flank face of the cutting tools on similar way of a grinding
wheel during machining of Al/SiC-MMC. Fig. 4 shows the
influence of cutting speed on the flank wear during turning of
Al/SiC-MMC. The turning operations were performed con-
sidering 0.5 mm/rev constant feed, 0.5 mm depth of cut and
for 50 mm continuous length of turning. From the figure, it
can be observed that at 20 m/min cutting speed flank wear
is only 0.07 mm whereas at 40 m/min cutting speed flank
wear is 0.15 mm. Experimental results revealed that when
cutting speed is doubled the flank wear goes up 2 times com-
pare to its value at low speed range. But when cutting speed
changes from 60 to 180 m/min the flank wear changes from
0.17 to 0.42 mm. It revels that when cutting speed is tripled
the flank wear goes up only 2.5 times compare to its value
at speed range 60180 m/min. From the figure, it can be ob-
served that when cutting speed increases above 100 m/min
the value of flank wear increases rapidly. Hence, the speed
range 60100 m/min is the best suitable cutting speed range
for low tool wear which in turn reduces machining cost of
Al/SiC-MMC. The influence of depth of cut on the flank
wear during turning of Al/SiC-MMC without use of coolant
is shown in Fig. 5. The turning operations were performed
considering 100 m/min cutting speed, 0.5 mm/rev feed and
for 50 mm length of continuous machining. It was observed
that at 0.25 mm depth of cut the flank wear is 0.1 mm, when
the depth of cut is double, i.e. 0.5 mm, wear increases to
0.2 mm, i.e. flank wear goes up to 2 times. Hence, from the
figure it can be concluded that the depth of cut is more sig-
nificant on the tool wear as compare to the feed at constant
cutting speed condition during machining of Al/SiC-MMC.
Fig. 6 shows the influence of feed on the flank wear at dif-
ferent cutting speeds during turning of Al/SiC-MMC without
use of coolant. At 60 m/min, where the feed is triple, i.e. from
0.25 to 0.75 mm/rev, the flank wear increases marginally
from 0.12 to 0.20 mm whereas for same change of feed,
when cutting speed is triple, i.e. from 60 to 180 m/min, the
flank wear goes up from 0.17 to 0.52 mm. It is evident that
cutting speeds are less susceptible to the flank wear as com-
pare to feed, hence, it is better to increase the feed rather
than increase the cutting speeds during machining of Al/SiC-
MMC.
3.3. Built-up edge
Fig. 7 shows the influence of the depth of cut on the BUE
during machining of Al/SiC-MMC without use of coolant.
The turning operations were performed considering constant
100 m/min cutting speed, 0.50 mm/rev feed and for 50 mm
continuous length of turning. From Fig. 7, it can be observed
that the BUE increase by increasing depth of cut. At 0.25 mm
depth of cut the BUE is 0.15 mm, whereas at 1.00 mm depth
of cut the BUE is 0.75 mm for same cutting speed, feed and
for 50 mm continuous length of machining. From Fig. 7, it
can also be observed that the BUE gradually increase by
increasing depth of cut during turning of Al/SiC-MMC.
1
Cutting sped: 100m/min
Built-up Edge,mm

0.8 Cutting speed: 100 m/min Feed: 0.5 mm/rev

0.8
Flank wea, mm

Feed rate: 0.5 mm/rev.

0.6 0.6
Length : 50 mm
0.4 0.4
0.2 0.2
0 0
0.25 0.5 0.75 1 1.25 1.5 0.25 0.5 0.75 1 1.25 1.5
Depth of cut (mm) Depth of cut, mm

Fig. 5. Influence of depth of cut (mm) on flank wear (mm). Fig. 7. Influence of depth of cut on BUE.
714 A. Manna, B. Bhattacharayya / Journal of Materials Processing Technology 140 (2003) 711716
Fig. 8. SEM of BUE formed during machining at different conditions.
Fig. 8(a)(c) shows the shapes of the BUEs during turn-
ing using specially geometrically design rhombic shaped
uncoated tungsten carbide insert. The SEM micrograph in
Fig. 8 (a) shows the shapes of the BUE at lower cutting speed
and feed with 0.5 mm depth of cut and for 50 mm length
of continuous turning, the height of the BUE is 1.10 mm.
The SEM micrographs in Fig. 8(b) shows the shapes of the
BUE at medium cutting speed and feed with 1 mm depth of
cut and for 50 mm length of continuous turning, the height
of the BUE is 1.05 mm. The SEM micrographs in Fig. 8(c)
shows the shape of the BUE at low cutting speed and low
feed with moderate depth of cut and for 50 mm length of
continuous turning, the height of the BUE is 1 mm. It is ob-
served from the micrograph that the chance of formation of
BUE is higher at lower cutting speed, feed and higher depth
of cut.
3.4. Chip formation
Fig. 9 shows the chips shapes formed during dry turning
of Al/SiC-MMC using uncoated carbide tools at constant
cutting speed, i.e. 100 m/min; feed, i.e. 0.50 mm/rev and
different depth of cuts. Fig. 9(a) shows the chips formed
at 0.50 mm depth of cut, 100 m/min cutting speed and
0.50 mm/rev feed. The most of the chips are formed in saw
tooth form with high radius curling circle and broken into
small pieces, i.e. 1/101/2 of the circle radius. Fig. 9(b)
shows the chips formed during dry turning at 1 mm depth
of cut.
From the chips appearance, it can be observed that the
frequent cracks and voids were formed on the outer face
of the chips. From Fig. 9 (b), it can also be observed that
the chips were formed in semi-continuous, semi-circular or
semi-parabolic or high parabolic saw tooth form with large
radius. The excessive voids were formed on the surface of
the chips due to the separation of SiC particles from Al-
matrix during formation of chips. Fig. 9(c) shows the shapes
of chips formed during dry turning at 1.25 mm depth of
cut. From Fig. 9(c), and appearance of the chips it can be
observed that the chips are formed in circular through curling
during machining and broken into semi-continuous form of
chips, i.e. 1/23/4 of the circle with comparatively small
radius. Fig. 9(d) shows the chips formed during dry turning
at 1.50 mm depth of cut. From the chip appearance it can be
observed that the curled and spiralled with saw toothed types
with small in length chips are formed during high depth of
cut.
The saw toothed and segmental types of chips together
with the wavy chip may be collectively called semi-
continuous chips. The addition of SiC particles reinforce-
ment into the aluminium matrix reduces the ductility and
makes the material ideal for producing saw-toothed and seg-
mental type chips during machining. During machining, it
can be observed that when the material undergone shear by
the movement of this cutting tool during the chip forming
process, cracks were initiated form the outside free surface
of the chip and some small voids were formed by the sepa-
ration of SiC particles and Al-matrix within the chip. Once
this material was sheared further, the coalescence of the
voids caused the crack, to grow and propagate in a zigzag
manner along the shear plane through the thickness of this
chip, as a result fracture take places and sliding of material
formed the saw toothed chips. It also observed that during
machining the propagation of this crack is accelerated by
the upward and side curling action of the chip, which from
time to time, helps break a long chip into smaller pieces.
The crack line of propagation through the matrix material
seems to develop along the stress concentration zone, i.e. at
the edge of the SiC particles inside the Al-matrix. The crack
line is propagated towards the boundary of the SiC particles
as Al/SiC interface seems to be a plane of weakness, i.e.
the matrix (Al)/reinforced particle (SiC) bond being weak.
Thus the crack propagates from SiC particle to SiC particle
 A. Manna, B. Bhattacharayya / Journal of Materials Processing Technology 140 (2003) 711716 715

Fig. 9. Microphotes of the chips formed at different conditions.

through some ductile fracture process through development
of fracture by overcoming the bonding strength between
the SiC particle and Al-matrix. From the close observation
of the chips, it can also be concluded that the pitch of the
chip formation becomes irregular with respect to the time
and this may be the caused due to the irregular distribution
of SiC particles into the Al-matrix, which initiates irregular
cracks from the outer surface of the workpiece.
3.5. Surface finish
Fig. 10 shows the influence of cutting speed on surface
roughness characteristics, i.e. Ra and Rt during turning of
Al/SiC-MMC without use of coolant. The turning operations
were performed considering 0.5 mm/rev constant feed and
0.5 mm depth of cut. The test results show that the value of
both surface roughness heights Ra and Rt are low at high
cutting speed and comparatively high at low cutting speed.
Some times during turning, it can be observed that the value
of surface roughness height (Rt ) is abruptly higher than the
trend value. The abrupt irregularity in the values of surface
roughness heights may be due to the presence of the hard
abrasive reinforced particle, i.e. SiC which are rolling over
the machined surface during turning and ploughing on the
turned surface which may generate grooves on the machined
surface.
The influence of feed on surface roughness heights Ra and
Rt during machining of Al/SiC-MMC without use of coolant
is also represented in Fig. 11. Experimental results show that
both the surface roughness heights Ra and Rt increase by in-
creasing feed. From the test results it can be concluded that
when feed is tripled, i.e. from 0.25 to 0.75 mm/rev the value
of surface roughness height Ra increases by 40% whereas
when cutting speed is tripled, i.e. from 60 to 180 m/min
the value of surface roughness height Ra decreases by 46%.

25
Ra
Surface roughness

25 20 Rt
Ra
heights (m)
heights (m)

20
roughness

15
Surface

Rt
15 Cutting speed: 100 m/min
Feed: 0.5 mm/rev
10 Depth of cut:.0.5mm 10 Depth of cut: 0.5 mm
5
5
0
20 40 60 100 150 180 225 0
Cutting speed (m/min) 0.14 0.25 0.33 0.50 .75 1
Feed (mm/rev.)
Fig. 10. Influence of cutting speed (m/min) on the surface roughness
height Ra (m) and Rt (m). Fig. 11. Influence of feed on the surface roughness height Ra and Rt .
716 A. Manna, B. Bhattacharayya / Journal of Materials Processing Technology 140 (2003) 711716
30 Cutting speed: 100 m/min
Surface roughness
25 Feed: 0.5 mm/rev
heights (m)
20
15
10
5
0
0.25 0.5 0.75 1 1.25
Depth of cut (mm)
Fig. 12. Influence of depth of cut on the surface roughness height Ra and
Rt .
Hence, it indicates that the cutting speed and feed has equal
influence on the surface finish if both are increased simul-
taneously.
Fig. 12 shows the influence of depth of cut on the sur-
face roughness heights Ra and Rt during machining of
Al/SiCMMC without use of coolant. From the depth of
cut versus surface finish graph, it can be observed that the
increase in depth of cut decreases the quality of surface
finish. The arithmetic average roughness height, Ra (m)
and maximum peak to valley of surface roughness height,
Rt (m) both increases by increasing depth of cut.
From the above explanation on the experimental results it
is clear that the cutting forces are increasing proportionally
with the increase in depth of cut and decreasing slightly with
the increase in cutting speed. It is observed that the selection
of higher cutting speeds during machining may cause faster
tool wear as compared to the higher cutting feeds.
Due to friction, high temperature and pressure the parti-
cles of the Al/SiC-MMC adhere to the cutting tool materials
during machining. In this way more particles will join up
with those already adhering and the so-called build up edge
is formed during turning of Al/SiC-MMC. Not only that,
due to the high friction and temperature between the chip of
aluminium matrix and the cutting tool, the chip metal welds
itself to the cutting tool edge. The welded chip material
further increases the friction and the friction again leads to
build up the localized layer upon layer and the so-called
BUE is formed during turning of Al/SiC-MMC. Generally,
BUE is formed between the chip and the rake face of the cut-
ting tool edge. It changes the actual rake angle, which may
change the direction of chip flow. The change of actual rake
angle changes the shear angle which may directly affected
the cutting force. Generally formation of BUE increases ac-
tual rake angle and consequently decreases the cutting force.
Whereas during turning of Al/SiC-MMC, it has been ob-
served that the BUE was formed at low speed and generated
higher cutting force (Pz ) and formation of poor surface fin-
ish. It is occur due to the presence of harder reinforced SiC
particle in the Al/SiC-MMC, which is not part off during
cutting at low speed by the action of the cutting tool edge.
Its rolls over the cutting tool edge and plough over the ma-
chined surface, which may cause of creation of high cutting
force. It is another cause of adhesive tool wear and formation
of poor surface finish during turning of Al/SiC-MMC.
Ra
Rt
4. Conclusions
1.5 Based on the performance and test results of the various
set of experiments performed for analysing the influence of
different machining parameters on the machinability char-
acteristics, e.g. cutting forces, tool wears, BUE, surface fin-
ish and chip formation during turning of Al/SiC-MMC uti-
lizing fixed rhombic tooling, i.e. CCGX-09-T3-04-Al-H10
type insert without use of coolant, the following points can
be observed as listed below:
(i) The flank wear rate is high at low cutting speed due to
the generation of high cutting forces and formation of
BUE during machining of Al/SiC-MMC.
(ii) Cutting speed zone between 60 and 150 m/min is rec-
ommended for machining of Al/SiC-MMC, where cut-
ting forces are more or less independent of cutting
speed.
(iii) The generation of BUE increase the actual rake angle
when machining of Al/SiC-MMC at low cutting speed
and it is found to correlate with the increment of cut-
ting forces which may in turn increase the cutting tool
wear.
(iv) Feed is less sensitive to the flank wear as compared to
the cutting speed. High speed, low feed and low depth
of cut are recommended for better surface finish.
Effective machining of Al/SiC-MMC is a challenge to
the manufacturing industries which mainly restrict the wide
spread application of this advance metal matrix composite in
practice. The fixed rhombic tooling of CCGX-09-T3-04-Al-
H10 type insert can be effectively used for proper machining
of Al/SiC-MMC.
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