Machining of Metal Matrix Composite

Presented By: Manjunath Shettar

Introduction
A metal matrix composite (MMC) is normally fabricated using a ductile metal (e.g., Al, Ti or Ni) as the base material, which is reinforced by a ceramic (e.g., alumina, SiC or graphite). Reinforcement & Matrix material will be having different properties. MMC properties - High strength, High modulus - High toughness & impact properties - Better wear resistance

Types of MMC

Particle reinforced composite Laminated composite Fiber reinforcement composite

Particulate reinforced MMCs are promising because of their homogeneous and isotropic material properties, low cost and ability to be formed using conventional metal processing techniques.

Types of Matrix Fiber

Matrix Cu base Fibers C, SiC, W Uses Combustion chamber, Nozzle Blades & Disc Shafts

Ni base & Inter metallic Al2O3 Ti base & Inter metallic TiB2

Al base
Mg base

SiC, C or Al2O3
Al2O3

Wings, Blades
Structural members

Process of producing MMC

Liquid State process - Casting or liquid infiltration - Squeeze casting - Stir casting Solid state process - Diffusion bonding - Powder processing

Machining of MMC

The main problem with machining is the wear of the cutting tool caused by direct contact with the hard particles or rather fibers in the insert. Thus abrasion and surface disruption are the dominant wear mechanisms. Increase in percentage of reinforcement produces more stress on tool.

An important aspect during the machining of metal matrix composites besides the tool wear is the quality of the machined surface. The damage occurs due to breakouts of particles and/or fibers from the surface during the cutting process.

Tools for Conventional Machining

The cutting materials PCD and diamond coatings, or thick layers, manufactured by the CVD process, are most suitable for machining fiber- or particlereinforced light metal matrix composites because they show a very high hardness due to the good wear resistance to abrasion. Due to the significantly higher hardness of CVDdiamond cutting materials, this material compared to PCD is less damaged by the SiC particles during turning.

Cutting speed is a key parameter

Design Parameters

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Benchmarks + 3 different CVD diamond-coated inserts Two speeds & three depths of cut Three test materials Tool life criterion - .4mm average flank wear In the preparation of specimens, three different average sizes for Al-powder (25, 100, 180 mm) and two different average sizes for SiC powder (10, 40 mm) will be used. For each size combination, specimens with four different percentages of SiC will be prepared (0, 5, 10, 20%).

Experimental Equipment

Turning - all inserts will be tested with turning

All operations done on a Lathe equipped with a dynamometric device CVD diamond-coated inserts with the setup CVD diamond-coated inserts with the setup

Milling

Drilling

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Procedure

Varying the cutting parameters like Cutting speed, feed and depth of cut at different level to find optimal parameters. After drilling 10 through holes for each experimental run, the degree of flank wear was measured by using optical microscope. Same for Turning and Milling operations.

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NTM

Abrasive Jet Machining Electro Discharge Machining Electro Chemical Machining

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Electro Discharge Machining

Machining parameters -Current - Pulse On Time - Voltage - Flushing pressure The response variables selected for this work are metal removal rate (MRR), tool wear rate (TWR) and surface roughness (SR).

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Conclusion

Al Base SiC, Particulate MMC will be produced by Stir Casting. Varying the cutting parameters in Machining of MMC to get optimal cutting features for conventional machining. Machining the MMC by NTM with different parameters.

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Thank You

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