Machinability Studies on Cast Aluminum Hybrid Composites Reinforced with Fly Ash Silicon Carbide and Graphioe Powder

Abstract

A metal matrix composite constitutes a continuous metallic matrix and a newlinediscontinuous phase known as reinforcement. When at least three materials are present in newlinea given composite, it is known as hybrid composite material. These hybrid metal matrix newlinecomposites (Hmmcs) have been used to manufacture drive shafts, disc brake rotors, brake newlinedrums, connecting rod pistons, engine block cylinder liners for automotive and rail vehicle newlineapplications. In general these Hmmcs exhibits improved stiffness, wear resistance and newlinetemperature capabilities and have emerged as an important class of material, which are newlineincreasingly being used in recent years. newlineThe Hmmcs castings of diameter 120 mm and length 300 mm was prepared through newlinesand mould technique following stir casting methodology. The Hmmcs castings found free newlinefrom surface defects, were further subjected to hardness, density, micro structure, XRD newlineanalysis, SEM and EDAX analysis, if the result of the analysis found OK, further casting newlineof diameter 120 mm and length 300 mm was prepared having 3%flyash, 3% silicon carbide newlineand 3% graphite filler content. The cast components were pre-processed for removal of fins newlineand machining rough cast surface before experimentation. The hardness of the Hmmcs newlinematerial measured using Brinell hardness tester and found greater than that of the matrix newlinealloy. The addition of fly ash and graphite particles has reduced the density of the Hmmcs newlineand further upon adding silicon carbide particulates, increase in the density of the Hmmcs newlinewas observed. The distribution of reinforcement particles in the aluminum matrix was newlineexamined using Czech Republic make TES CAN VEGA-3 LMU Scanning Electron newlineMicroscope. The stir mixing method has resulted in the homogeneous distribution of fly newlineash, silicon carbide particles and graphite powder with minimum porosity in the Hmmcs. newlineThe experimental results revealed that the coating thickness of the coated insert used for newlinethe experiment was measured 4.84 microns. newlineSingle point cutting tools of various tool sign