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Influence of Machining Parameter on Tool Life While Machining Hybrid Metal Matrix Composites

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Document pages: 19 pages

Abstract: A metal matrix composite constitutes a continuous metallic matrix and a discontinuous phase known as reinforcement. Thehybrid metal matrix composites (Hmmcs) have been used to manufacturedrive shafts, disc brake rotors, brake drums, connecting rods pistons, engineblock cylinder liners for automotive and rail vehicle applications. The Hmmcscastings of diameter 120 mm and length 300 mm were prepared through sand mouldtechnique following stir casting methodology. The cast components furthersubjected to evaluation of physical properties and machining tests using twogrades of coated inserts and PCD inserts. The experiments were carried outfollowing ISO 3685 standards. The coating thickness of the TiN coated and TiAlNcoated inserts were measured using Kalo testing method; the results of the test show that the interface ofthe substrate and coating was free from the porosity, and the coating thicknessof TiN coating was 4.84 microns and TiAlN coating was measured 4.6 microns. Theresults of the experiments show that performance of the PCD insert was betterthan coated inserts at 0.1 mm rev feed; however at 0.2 mm revolution feed PCD insert failedby micro chipping of cutting edge while machining Hmmcs. When TiAlN coatedinserts were used to machine Hmmcs the coated inserts failed by gradual wearand BUE formation.

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