K. Palanikumar and R. Karthikeyan
Aluminium silicon carbide reinforced metal matrix composite (Al/SiC‐MMC) materials are rapidly replacing conventional materials in various automotive, aerospace and other…
Abstract
Aluminium silicon carbide reinforced metal matrix composite (Al/SiC‐MMC) materials are rapidly replacing conventional materials in various automotive, aerospace and other industries. Accordingly, the need for accurate machining of composites has increased enormously. The present work analyzes the machining of Al/SiC composites for surface roughness. An empirical model has been developed to correlate the machining parameters and their interactions with surface roughness. Response surface regression and analysis of variance are used for making the model. The developed model can be effectively used to predict the surface roughness in machining Al/SiC‐MMC composites. The influences of different parameters in machining Al/SiC particulate composites have been analyzed through contour graphs and 3D plots.
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Shubhajit Das, Chandrasekaran M., Sutanu Samanta, Palanikumar Kayaroganam and Paulo Davim J.
Composite materials are replacing the traditional materials because of their remarkable properties and the addition of nanoparticles making a new trend in material world. The nano…
Abstract
Purpose
Composite materials are replacing the traditional materials because of their remarkable properties and the addition of nanoparticles making a new trend in material world. The nano addition effect on tribological properties is essential to be used in automotive and industrial applications. The current work investigates the sliding wear behavior of an aluminum alloy (AA) 6061-based hybrid metal matrix composites (HMMCs) reinforced with SiC and B4C ceramic nanoparticles.
Design/methodology/approach
The hybrid composites are fabricated using stir casting process. Two different compositions were fabricated by varying the weight percentage of the ceramic reinforcements. An attempt has been made to study the wear and friction behavior of the composites using pin-on-disc tribometer to consider the effects of sliding speed, sliding distance and the normal load applied.
Findings
The tribological tests are carried out and the performances were compared. Increase in sliding speed to 500 rpm resulted in the rise of temperature of the contacting tribo-surface which intensified the wear rate at 30N load for the HMMC. The presence of the ceramic particles further reduced the contact region of the mating surface thus reducing the coefficient of friction at higher sliding speeds. Oxidation, adhesion, and abrasion were identified to be the main wear mechanisms which were further confirmed using energy dispersive spectroscopy and field emission scanning electron microscopy (FESEM) of the worn out samples.
Practical implications
The enhancement of wear properties is achieved because of the addition of the SiC and B4C ceramic nanoparticles, in which these composites can be applied to automobile, aerospace and industrial products where the mating parts with less weight is required.
Originality/value
The influence of nanoparticles on the tribological performance is studied in detail comprising of two different ceramic particles which is almost new research. The sliding effect of hybrid composites with nano materials paves the way for using these materials in engineering and domestic applications.
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Jiaqi Pan, Xiaoshan Liu, Guoqiu He, Bin Ge, Peiwen Le, Jingquan Li and Zhiqiang Zhou
The purpose of this paper is to understand the effect of particle content, applied load and sliding speed on the tribological properties of A356-SiCP composites manufactured using…
Abstract
Purpose
The purpose of this paper is to understand the effect of particle content, applied load and sliding speed on the tribological properties of A356-SiCP composites manufactured using a newly developed vacuum stir casting technique.
Design/methodology/approach
A356 alloy reinforced with 10, 15 and 20 vol% SiC particles was prepared by vacuum stir casting. Tribological tests were carried out on block-on-ring tribometer under dry sliding conditions, room temperature. Wear mechanism was investigated by scanning electron microscope and energy dispersion spectrum.
Findings
SiCP is homogeneously dispersed in the matrix. The increase in SiCP content decrease wear rate, but it leads to an increase in coefficient of friction. The wear rate increase and friction coefficient present different variation trends with increasing load. For A356-20%SiCP composite, when the load is less than 10 MPa, wear rate and friction coefficient under sliding speed of 400 rpm are lower than those of 200 rpm. Wear mechanism transition from abrasion, oxidation, delamination, adhesion to plastic flow as load and sliding speed increasing.
Practical implications
Results of this study will help guide the use of A356-SiCP in many automotive products such as brake rotors, brake pads, brake drums and pistons.
Originality/value
There are few paper studies the effect of particle content, applied load and sliding speed on the tribological properties of A356-SiCP composites. Aluminum matrix composites with uniform distribution of reinforcing particles were successfully prepared by using the newly developed vacuum stir casting technique.
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Amrinder Pal Singh, Manu Sharma and Inderdeep Singh
Damage induced during drilling of polymer matrix composites depends upon torque during drilling. Modeling of torque with feed rate and its control becomes imminent for damage free…
Abstract
Purpose
Damage induced during drilling of polymer matrix composites depends upon torque during drilling. Modeling of torque with feed rate and its control becomes imminent for damage free drilling of composite laminates. Therefore, the purpose of this paper is to construct a transfer function between drilling torque and feed rate based upon experiments. Thereafter, the torque is controlled by using PID controller.
Design/methodology/approach
This paper presents step-by-step procedure to capture complex drilling dynamics of polymer matrix composites in a mathematical model. A glass fiber reinforced plastic (GFRP) composite laminate is drilled at constant feed rate during experimentation. The corresponding time response of torque is recorded. First order, second order and third order transfer functions between torque and feed rate are identified using system identification toolbox of Matlab®. These transfer functions are then converted into state-space models. Experimental verification is performed on GFRP composite laminate. PID controller is designed using Simulink® to track a given reference torque during drilling of polymer matrix composite. The controller is then validated using different reference torque trajectories.
Findings
Good match is observed between torque response from state-space models and experiments. Error analysis based on integral absolute error and integral squared error on experimental and simulated response show that third-order system represents the complex drilling dynamics in a better way than first and second-order systems. PID controller effectively tracks given reference trajectories.
Originality/value
Third-order model between torque and feed rate for drilling of composites not available in literature has been presented. PID controller has previously been applied successfully for drilling of conventional materials, this paper extends implementation of PID torque control for drilling of composites.
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N. Radhika, S. Babudeva Senapathi, R. Subramaniam, Rahul Subramany and K.N. Vishnu
The purpose of this paper is surface roughness prediction using pattern recognition for the aluminium hybrid metal matrix composite (HMMC).
Abstract
Purpose
The purpose of this paper is surface roughness prediction using pattern recognition for the aluminium hybrid metal matrix composite (HMMC).
Design/methodology/approach
Hybrid composites were manufactured using liquid metallurgy technique. The cast HMMC was machined using an industrial CNC turning centre and the machining vibration signals were acquired using an accelerometer. The acquired signals were processed and used to build a machine learning model for predicting surface finish based on the tool signature.
Findings
The authors established a technique for predicting and monitoring the surface quality during machining using a low cost accelerometer. It is capable of being integrated with the machine controller for online warning of deviations in surface roughness. The system is reconfigurable for any machining condition with a very short training period. The use of this model facilitates online surface roughness monitoring, avoiding the need for costly measuring equipment.
Originality/value
The model developed is innovative and not reported widely to the best of the authors' knowledge. The use of accelerometer‐based surface roughness prediction and control is an innovative approach for automation of machining process monitoring. These can be integrated into any existing machining centre as a standalone system or can be integrated into the CNC controller like Fanuc or Siemens.
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M.P. Jenarthanan, Venkata Sai Sunil Gujjalapudi and Venkatraman V.
The purpose of this paper is to originate a statistical model for delamination factor, surface roughness, machining force and also to determine and compare the effects of…
Abstract
Purpose
The purpose of this paper is to originate a statistical model for delamination factor, surface roughness, machining force and also to determine and compare the effects of machining parameters (spindle speed, fiber orientation angle, helix angle and feed rate) on the output responses during end-milling of glass fiber reinforced polymers (GFRP) by using desirability functional analysis (DFA) and grey relational analysis (GRA).
Design/methodology/approach
Based on Taguchi’s L27 orthogonal array, milling experiments were carried on GFRP composite plates employing solid carbide end mills with different helix angles. The machining parameters were optimized by an approach based on DFA and GRA, which were useful tools for optimizing multi-response considerations, namely, machining force, surface roughness and delamination factor. A composite desirability index was obtained for multi-responses using individual desirability values from DFA. Based on this index and grey relational grade the optimum levels of parameters were identified and significant contribution of parameters was ascertained by analysis of variance.
Findings
Fiber orientation angle (66.75 percent) was the significant parameter preceded by feed rate (15.05 percent), helix angle (7.76 percent) and spindle speed (0.30 percent) for GFRP composite plates.
Originality/value
Multi-objective optimization in end-milling of GFRP composites using DFA and GRA has not been performed yet.
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M.P. Jenarthanan, Raahul Kumar S and Vinoth S
This study aimed to develop a mathematical model for delamination and surface roughness during end milling by using grey relational analysis (GRA) and to determine how the input…
Abstract
Purpose
This study aimed to develop a mathematical model for delamination and surface roughness during end milling by using grey relational analysis (GRA) and to determine how the input parameters (cutting speed, depth of cut, helix angle and feed rate) influence the output response (delamination and surface roughness) in machining of hybrid glass fibre-reinforced plastic (GFRP) (abaca and glass) composite using solid carbide end mill cutter.
Design/methodology/approach
The Four factors, three levels Taguchi orthogonal array design in GRA is used to conduct the experimental investigation. The Shop Vision inspection system is used to measure the width of maximum damage of the machined hybrid GFRP composite. The Shop Handysurf E-35A surface roughness tester is used to measure the surface roughness of the machined hybrid GFRP composite. “Minitab 14” is used to analyse the data collected graphically. Analysis of variance is conducted to validate the model in determining the most significant parameter.
Findings
The GRA is used to predict the input factors influencing the delamination and surface roughness on the machined surfaces of the hybrid GFRP composite at different cutting conditions with the chosen range of 95 per cent confidence intervals. Analysis on the influences of the entire individual input machining parameters on the delamination and surface roughness has been conducted using GRA.
Originality/value
Effect of milling of the hybrid GFRP composite on delamination and surface roughness with various helix angle solid carbide end mill has not been analysed yet using the GRA technique.
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Naresh Neeli, M.P. Jenarthanan and G. Dileep Kumar
The purpose of this paper is to optimise the process parameters, namely, fibre orientation angle, helix angle, spindle speed, and feed rate in milling of glass fibre-reinforced…
Abstract
Purpose
The purpose of this paper is to optimise the process parameters, namely, fibre orientation angle, helix angle, spindle speed, and feed rate in milling of glass fibre-reinforced plastic (GFRP) composites using grey relational analysis (GRA) and desirability function analysis (DFA).
Design/methodology/approach
In this work, experiments were carried out as per the Taguchi experimental design and an L27 orthogonal array was used to study the influence of various combinations of process parameters on surface roughness and delamination factor. As a dynamic approach, the multiple response optimisation was carried out using GRA and DFA for simultaneous evaluation. These two methods are best suited for multiple criteria evaluation and are also not much complicated.
Findings
The process parameters were found optimum at a fibre orientation angle of 15°, helix angle of 25°, spindle speed of 6,000 rpm, and a feed rate of 0.04 mm/rev. Analysis of variance was employed to classify the significant parameters affecting the responses. The results indicate that the fibre orientation angle is the most significant parameter preceded by helix angle, feed rate, and spindle speed for GFRP composites.
Originality/value
An attempt to optimise surface roughness and delamination factor together by combined approach of GRA and DFA has not been previously done.
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– The purpose of this paper is to understand the effect of graphite content on the properties of aluminum alloy/silicon carbide/granite (Al/SiC/Gr) composites.
Abstract
Purpose
The purpose of this paper is to understand the effect of graphite content on the properties of aluminum alloy/silicon carbide/granite (Al/SiC/Gr) composites.
Design/methodology/approach
Hardness and wear tests were applied to the powder metallurgical composites, and microstructural characterization was conducted.
Findings
Optimum graphite content for maximum wear resistance is reported as weight 6 per cent.
Originality/value
Results of this study may help light weight Al/SiC/Gr composites to be used in different industrial applications.
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M.P. Jenarthanan, R. Gokulakrishnan, B. Jagannaath and P. Ganesh Raj
The purpose of this paper is to find out the optimum machining parameters using Taguchi technique with principal component analysis (PCA) during end milling of GFRP composites.
Abstract
Purpose
The purpose of this paper is to find out the optimum machining parameters using Taguchi technique with principal component analysis (PCA) during end milling of GFRP composites.
Design/methodology/approach
In multi-objective optimization, weight criteria of each objective are important for producing better and accurate solutions. This method has been employed for simultaneous minimization of surface roughness, cutting force and delamination factor. Experiments were planned using Taguchi’s orthogonal array with the machining parameters, namely, helix angle of the end mill cutter, spindle speed, feed rate and depth of cut were optimized with considerations of multiple response characteristics, including machining force, surface roughness and delamination as the responses. PCA is adopted to find the weight factors involved for all objectives. Finally analysis of variance concept is employed on multi-SN ratio to find out the relative significance of machining parameter in terms of their percentage contribution.
Findings
The multi-SN ratio is achieved by the product of weight factor and SN ratio to the performance characteristics in the utility concept. The results show that a combination of machining parameters for the optimized results has helix angle of 35°, machining speed of 4,000 m/min, feed rate of 750 mm/rev and depth of cut of 2.0 mm.
Originality/value
Effect of milling of GFRP composites on delamination factor, surface roughness and machining force with various helix angle solid carbide end mill has not been analysed yet using PCA techniques.