Experimental investigations on wear and machining characterisitics of aluminium hybrid composites

Abstract

A composite is a combination of two or more dissimilar materials having a distinct interface between them such that the properties of the resulting material are superior to the individual consittutents. Among the different classes of composites, Metal Matrix Composites (MMCs) are widely used in many industries. Aluminium Matrix Composites (AMCs) refer to the class of light weight, high performance aluminium centric materials system. Most of the engineers often face the problem of selection of appropriate and optimum combination of input factors for achieving the required weight loss, tool wear rate, metal removal rate and surface roughness. Unit recently, trial and error methods were used to determine the optimum input factors for the required weight loss, tool wear rate, metal removal rate and surface roughness which results in wastage of cost and time. With a view to solve the above problems in metal matrix composites, an attempt was made to study the various aspects of composites such as regression and Artificial Neural Network modeling (ANN) of weight loss, regression modeling of metal removal rate, tool wear rate and surface roughness, micro structure, hardness and heat treatment. Wear tests were conducted using a pin)on)disc apparatus. Influencing factors such as weight percentage of SiC and graphite particles, applied load and sliding distance, which affecting the weight loss were identified. The machining characteristics were studied using an Electric Discharge Machine (EDM).The factors affecting metal removal rate, tool wear rate and surface roughness were identified. All the above analysis and results on wear properties, machining characteristics of hybrid composites can be very useful for the manufacturing industries for predicting weight loss and machining characteristics. The results from hardness, microstructure and heat treatment are also very useful for the composite parts manufacturing industries especially for automotive industries for making composite brake drum for cars. newline