| Experimental Investigations on Effect of Ceramic B C
Particulate Addition on Cutting Forces and Surface
Roughness during Turning of 6061Al Alloy |
Vijaykumar Hiremath, V. Auradi 1, * 1 and S. T. Dundur2
pages : 126 132
DOI : 10.1080/0371750X.2016.1164626 |
| Abstract |
| Aluminium matrix composites are of great interest for researchers in recent years because
of their excellent combinations of engineering properties over traditional materials. The
machinability of these aluminium matrix composites has become vital for manufacturing
industries. During machining of aluminium matrix composites, the cutting forces and
surface roughness are dependent on machining parameters (feed rate, cutting speed and
depth of cut) and manufacturing parameters (size of the particles, volume fraction,
porosity, hardness). With this backdrop, the present work is aimed at investigating the
effect of machining parameters, viz. cutting speed, feed rate and depth of cut on the cutting
force components, namely, feed force ( ), radial force ( ), cutting force ( ) and surface
roughness. The experiments were performed on 0, 5, 7 and 9 wt% B C particulate of 88 μm
size reinforced composite specimens. The prepared specimens were subjected to turning
operation on a conventional lathe machine using polycrystalline diamond (PCD) tool to
evaluate the effect of B C particulate addition with varying percentages on cutting forces
and surface roughness. Results reveal that the cutting force components decrease with
the increase in the wt% of ceramic B C particulate reinforcement, which can be attributed
mainly to increase in porosity, hardness and dislocation densities. SEM image obtained
from composite having low wt% of ceramic B C particulates (5 wt%), which is machined at
higher cutting speed and higher depth of cut, has clearly shown the presence of built-up
edge (BUE) at the tip of polycrystalline diamond tool. Further, cutting forces increased with
increase in feed rate and depth of cut for both 6061Al matrix and 6061Al-B C composites. It
is observed that the surface quality is significantly improved when the cutting speed is
increased, and depth of cut and feed rate are decreased.
[Keywords: 6061Al, Ceramic B C particulates, Cutting force, Feed force, Radial force,
Built-up edge, PCD] |
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