The Effect of Machining Parameters on the Cutting Forces, Tool Wear, and Machined Surface Roughness of Metal Matrix Nano Composite Material

E. Y. El-Kady; A. M. Gaafer; M. H. G. Ghaith; T. Khalil; A. A. Mostafa

doi:doi:10.11648/j.am.20150403.11

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The Effect of Machining Parameters on the Cutting Forces, Tool Wear, and Machined Surface Roughness of Metal Matrix Nano Composite Material

E. Y. El-Kady, A. M. Gaafer, M. H. G. Ghaith, T. Khalil, A. A. Mostafa

Published in Advances in Materials (Volume 4, Issue 3)

Received: 13 March 2015 Accepted: 7 April 2015 Published: 23 April 2015

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Abstract

The aim of the present study is to investigate the effect of machining parameters on the cutting forces, tool wear, and machined surface roughness of metal matrix nano composite material through dry turning operations. Composites specimens manufactured from aluminum alloy metal matrix and reinforced with different weight fractions of silicon carbide nano particulates were used to conduct the experimental work. Stir-casting method followed by squeezing technique were used to fabricate the nano composites specimens. The machinability tests were conducted through different cutting conditions using carbide inserts tools material. The machinability characteristics such as surface roughness of the machined specimens, types of chip, cutting forces in the direction of main cutting motion, and tool wear were investigated through the experimental conditions. The results showed improve in surface roughness by increasing the cutting speed and the weight fraction percent of the SiC nanoparticulates. On the other hand the main cutting force component as well as tool flank wear were increased by increasing the weight fraction of SiC nanoparticulates. Moreover the force component increased with increasing the feed rate and depth of cut, however the cutting forces were decreased by increasing the cutting speed while the flank wear increase.

Published in	Advances in Materials (Volume 4, Issue 3)
DOI	10.11648/j.am.20150403.11
Page(s)	43-50
Creative Commons	This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
Copyright	Copyright © The Author(s), 2015. Published by Science Publishing Group

Keywords

Nano-Composites, Machining parameters, Cutting Forces, Tool Wear, Types of Chip, Surface Roughness

References

[1]	Luis, M. P., “MACHINING OF HYBRID COMPOSITES” PhD. Thesis Faculty of Engineering – University of Porto 2005;
[2]	Nikhilesh Chawla & Yu-Lin Shen., “Mechanical Behavior of Particle Reinforced Metal Matrix Composites”, Advanced Engineering Materials, Vol. 3 No. 6, 2001, PP. 357-370.
[3]	Payodhar, P & Sachikanta, K., “A Novel route for development of Bulk Al/SiC Metal Matrix Nano Composites”, Journal of Nanotechnology, Vol. 2011, 5 pages.
[4]	A. Manna, B. Bhattacharayya., “A study on machinability of Al/SiC-MMC” Journal of Materials Processing Technology 2003, PP. 711-716.
[5]	M. Z. Zahran, E. Y. El-Kady, M. H. Gheith, M. Abdel-Fattah., “Machinability of Nickel Particulates-Reinforced(AA6063) Aluminum Based Alloy”., Ain Shams University Scientific Bulletin Vol.42 No.1, 2007, PP. 777-796.
[6]	E. Y El-Kady., “Machinability of Squeeze Casting MMCs A-390 Reinforced with SiC and Al2O3 Particulate” Scientific Bulletin of Ain Shams University, Faculty of Engineering, Vol. 38, No. 4 December 2003, PP. 867-886.
[7]	Chambers AR, Stephens SE. “Machining of A1-5Mg reinforced with 5 vol.% Saffil and 15 vol.% SiC”. Materials Science and Engineering; 1991, A135:287–90.
[8]	S. BARNES and I. R. PASHBY., “Machining of Aluminum Based Metal Matrix Composites” Department of Engineering, University of Warwick, England, Applied Composite Materials, Vol. 2 1995, PP, 31-42.
[9]	S. A. Sajjadi, H. R. Ezatpour & M. Torabi Parizi., “Comparison of Microstructure and Mechanical Properties of A356 Aluminum Alloy/Al2O3 Composites Fabricated by Stir and Compocasting Process” Materials and Design 34 (2012) PP. 106-111.
[10]	E. Y El-Kady, T. S. Mahmoud & M. H. G. Ghaith., “Machinability of A356/Al2O3 Cast Aluminum Metal Matrix Nanocomposites (MMCs)”, Material Science Vol. 9 Issue 1, 2013 PP. 1-7.
[11]	Brintha. N. C., Shajulin B. and Winowlin Jappes J. T “Machining Parameter Optimization of Al/SiCp Composite Materials Using Genetic Algorithm. International Journal of Engineering Research and Technology, Vol. 2 Issue 6 (2013), PP., 691-702.

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APA Style

E. Y. El-Kady, A. M. Gaafer, M. H. G. Ghaith, T. Khalil, A. A. Mostafa. (2015). The Effect of Machining Parameters on the Cutting Forces, Tool Wear, and Machined Surface Roughness of Metal Matrix Nano Composite Material. Advances in Materials, 4(3), 43-50. https://doi.org/10.11648/j.am.20150403.11

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ACS Style

E. Y. El-Kady; A. M. Gaafer; M. H. G. Ghaith; T. Khalil; A. A. Mostafa. The Effect of Machining Parameters on the Cutting Forces, Tool Wear, and Machined Surface Roughness of Metal Matrix Nano Composite Material. Adv. Mater. 2015, 4(3), 43-50. doi: 10.11648/j.am.20150403.11

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AMA Style

E. Y. El-Kady, A. M. Gaafer, M. H. G. Ghaith, T. Khalil, A. A. Mostafa. The Effect of Machining Parameters on the Cutting Forces, Tool Wear, and Machined Surface Roughness of Metal Matrix Nano Composite Material. Adv Mater. 2015;4(3):43-50. doi: 10.11648/j.am.20150403.11

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@article{10.11648/j.am.20150403.11,
  author = {E. Y. El-Kady and A. M. Gaafer and M. H. G. Ghaith and T. Khalil and A. A. Mostafa},
  title = {The Effect of Machining Parameters on the Cutting Forces, Tool Wear, and Machined Surface Roughness of Metal Matrix Nano Composite Material},
  journal = {Advances in Materials},
  volume = {4},
  number = {3},
  pages = {43-50},
  doi = {10.11648/j.am.20150403.11},
  url = {https://doi.org/10.11648/j.am.20150403.11},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.am.20150403.11},
  abstract = {The aim of the present study is to investigate the effect of machining parameters on the cutting forces, tool wear, and machined surface roughness of metal matrix nano composite material through dry turning operations. Composites specimens manufactured from aluminum alloy metal matrix and reinforced with different weight fractions of silicon carbide nano particulates were used to conduct the experimental work. Stir-casting method followed by squeezing technique were used to fabricate the nano composites specimens. The machinability tests were conducted through different cutting conditions using carbide inserts tools material. The machinability characteristics such as surface roughness of the machined specimens, types of chip, cutting forces in the direction of main cutting motion, and tool wear were investigated through the experimental conditions. The results showed improve in surface roughness by increasing the cutting speed and the weight fraction percent of the SiC nanoparticulates. On the other hand the main cutting force component as well as tool flank wear were increased by increasing the weight fraction of SiC nanoparticulates. Moreover the force component increased with increasing the feed rate and depth of cut, however the cutting forces were decreased by increasing the cutting speed while the flank wear increase.},
 year = {2015}
}

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TY - JOUR
T1 - The Effect of Machining Parameters on the Cutting Forces, Tool Wear, and Machined Surface Roughness of Metal Matrix Nano Composite Material
AU - E. Y. El-Kady
AU - A. M. Gaafer
AU - M. H. G. Ghaith
AU - T. Khalil
AU - A. A. Mostafa
Y1 - 2015/04/23
PY - 2015
N1 - https://doi.org/10.11648/j.am.20150403.11
DO - 10.11648/j.am.20150403.11
T2 - Advances in Materials
JF - Advances in Materials
JO - Advances in Materials
SP - 43
EP - 50
PB - Science Publishing Group
SN - 2327-252X
UR - https://doi.org/10.11648/j.am.20150403.11
AB - The aim of the present study is to investigate the effect of machining parameters on the cutting forces, tool wear, and machined surface roughness of metal matrix nano composite material through dry turning operations. Composites specimens manufactured from aluminum alloy metal matrix and reinforced with different weight fractions of silicon carbide nano particulates were used to conduct the experimental work. Stir-casting method followed by squeezing technique were used to fabricate the nano composites specimens. The machinability tests were conducted through different cutting conditions using carbide inserts tools material. The machinability characteristics such as surface roughness of the machined specimens, types of chip, cutting forces in the direction of main cutting motion, and tool wear were investigated through the experimental conditions. The results showed improve in surface roughness by increasing the cutting speed and the weight fraction percent of the SiC nanoparticulates. On the other hand the main cutting force component as well as tool flank wear were increased by increasing the weight fraction of SiC nanoparticulates. Moreover the force component increased with increasing the feed rate and depth of cut, however the cutting forces were decreased by increasing the cutting speed while the flank wear increase.
VL - 4
IS - 3
ER -

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Author Information

E. Y. El-Kady

Benha University, Faculty of Engineering at Shoubra, Cairo, Egypt
A. M. Gaafer

Benha University, Faculty of Engineering at Shoubra, Cairo, Egypt
M. H. G. Ghaith

King Khalid University (KKU), Department of Mechanical Engineering, Abha, Kingdom of Saudi Arabia (KSA)
T. Khalil

Benha University, Faculty of Engineering at Shoubra, Cairo, Egypt
A. A. Mostafa

Benha University, Faculty of Engineering at Shoubra, Cairo, Egypt

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APA Style

E. Y. El-Kady, A. M. Gaafer, M. H. G. Ghaith, T. Khalil, A. A. Mostafa. (2015). The Effect of Machining Parameters on the Cutting Forces, Tool Wear, and Machined Surface Roughness of Metal Matrix Nano Composite Material. Advances in Materials, 4(3), 43-50. https://doi.org/10.11648/j.am.20150403.11

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ACS Style

E. Y. El-Kady; A. M. Gaafer; M. H. G. Ghaith; T. Khalil; A. A. Mostafa. The Effect of Machining Parameters on the Cutting Forces, Tool Wear, and Machined Surface Roughness of Metal Matrix Nano Composite Material. Adv. Mater. 2015, 4(3), 43-50. doi: 10.11648/j.am.20150403.11

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AMA Style

E. Y. El-Kady, A. M. Gaafer, M. H. G. Ghaith, T. Khalil, A. A. Mostafa. The Effect of Machining Parameters on the Cutting Forces, Tool Wear, and Machined Surface Roughness of Metal Matrix Nano Composite Material. Adv Mater. 2015;4(3):43-50. doi: 10.11648/j.am.20150403.11

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@article{10.11648/j.am.20150403.11,
  author = {E. Y. El-Kady and A. M. Gaafer and M. H. G. Ghaith and T. Khalil and A. A. Mostafa},
  title = {The Effect of Machining Parameters on the Cutting Forces, Tool Wear, and Machined Surface Roughness of Metal Matrix Nano Composite Material},
  journal = {Advances in Materials},
  volume = {4},
  number = {3},
  pages = {43-50},
  doi = {10.11648/j.am.20150403.11},
  url = {https://doi.org/10.11648/j.am.20150403.11},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.am.20150403.11},
  abstract = {The aim of the present study is to investigate the effect of machining parameters on the cutting forces, tool wear, and machined surface roughness of metal matrix nano composite material through dry turning operations. Composites specimens manufactured from aluminum alloy metal matrix and reinforced with different weight fractions of silicon carbide nano particulates were used to conduct the experimental work. Stir-casting method followed by squeezing technique were used to fabricate the nano composites specimens. The machinability tests were conducted through different cutting conditions using carbide inserts tools material. The machinability characteristics such as surface roughness of the machined specimens, types of chip, cutting forces in the direction of main cutting motion, and tool wear were investigated through the experimental conditions. The results showed improve in surface roughness by increasing the cutting speed and the weight fraction percent of the SiC nanoparticulates. On the other hand the main cutting force component as well as tool flank wear were increased by increasing the weight fraction of SiC nanoparticulates. Moreover the force component increased with increasing the feed rate and depth of cut, however the cutting forces were decreased by increasing the cutting speed while the flank wear increase.},
 year = {2015}
}

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