TITLE:
Influence of Machining Parameter on Tool Life While Machining Hybrid Metal Matrix Composites
AUTHORS:
C. R. Prakash Rao, V. Ravi Kumar, D. V. Ravi Kumar, Poorna Chandra, M. Vedavyasa, M. S. Rajagopal
KEYWORDS:
Composites, Hybrid Metal Matrix Composites, Coated Inserts, PCD Inserts, Turning, Tool Life Testing
JOURNAL NAME:
Journal of Minerals and Materials Characterization and Engineering,
Vol.8 No.6,
November
6,
2020
ABSTRACT: A metal matrix composite constitutes a continuous metallic matrix and a discontinuous phase known as reinforcement. The
hybrid metal matrix composites (Hmmcs) have been used to manufacture
drive shafts, disc brake rotors, brake drums, connecting rods pistons, engine
block cylinder liners for automotive and rail vehicle applications. The Hmmcs
castings of diameter 120 mm and length 300 mm were prepared through sand mould
technique following stir casting methodology. The cast components further
subjected to evaluation of physical properties and machining tests using two
grades of coated inserts and PCD inserts. The experiments were carried out
following ISO 3685 standards. The coating thickness of the TiN coated and TiAlN
coated inserts were measured using Kalo testing method; the results of the test show that the interface of
the substrate and coating was free from the porosity, and the coating thickness
of TiN coating was 4.84 microns and TiAlN coating was measured 4.6 microns. The
results of the experiments show that performance of the PCD insert was better
than coated inserts at 0.1 mm/rev feed; however at 0.2 mm/revolution feed PCD insert failed
by micro chipping of cutting edge while machining Hmmcs. When TiAlN coated
inserts were used to machine Hmmcs the coated inserts failed by gradual wear
and BUE formation.