Department of Mechanical Engineering, Chaitanya Bharathi Institute of Technology Gandipet, Hyderabad – 500 075, AP, India.
The machining of composites is a significant challenge to the industry. A rapid tool wear in MMCs increases the machining cost. A turning test on Metal Matrix Composites (MMCs) is performed with k-20 carbide tool and HSS tool material and the wear patterns and wear land growth rates were analysed to clarify the relationship between Physical (Mechanical) properties and flank wear of cutting tools. The main results obtained are as follows:
With the increase of cutting speed, the rate of wear on nose and flank was studied.
The effect of cutting speed and the width of cut on machining characteristics of Metal Matrix composites were investigated.
The flank wear rate was quantified by considering the tool geometry.
Further modelling techniques on continuous chip formation by using the commercial FEM code ANSYS LS-DYNA are discussed. A combination of three chip formation analysis steps including initial chip formation, chip growth and steady-state chip formation is used to simulate the continuous chip formation process. In this cutting process steady state analysis is performed to predict the contact pressure (normal stress) at tool/chip interface and tool/work interface, relative sliding velocity and cutting temperature distribution. It is shown that tool wear rate is dependent on these cutting process variables and their relationship is described by wear rate models then tool wear progress in turning operation is estimated.
Metal Matrix composites (MMCs), Mechanics of chip removal, Experimental techniques, Cutting speed, Cutting Force, Wear rate, Finite element modelling, Heat Transfer, Analysis
