Investigation of the tool wear, surface roughness, and chip formation in the machining of ZrO 2 -reinforced aluminum com
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(2020) 42:565
REVIEW PAPER
Investigation of the tool wear, surface roughness, and chip formation in the machining of ZrO2‑reinforced aluminum composites Muharrem Pul1 Received: 18 January 2020 / Accepted: 25 September 2020 © The Brazilian Society of Mechanical Sciences and Engineering 2020
Abstract The aim of this study is to reveal how ZrO2 (zirconia) contributes to the machinability of aluminum 1050. In the first stage of this study, composite materials were produced by the vortex method by adding different amounts of Z rO2 (5%, 10%, 20%, and 30%) into commercial aluminum of 99.5% purity. Then, microstructure images of composite materials were taken under the scanning electron microscope (SEM), and the hardness of these composite materials was measured. In the last stage, the machinability tests of the composite materials were performed on the lathe under dry machining conditions at 125, 175, and 225 m/min cutting speeds and 0.03–0.06 and 0.12 mm/rev feed rates, with 1.5 mm constant depth of cut. Uncoated cementite carbide cutting tool inserts were used in machining tests. SEM images of the cutting tool inserts were taken, and the roughness values of the machined surfaces were measured. Chip samples were taken and investigated. It was observed that all the cutting tools had a Built-Up Edge (BUE) formation. Surface roughness and BUE formation increased as the feed rates were increased and decreased with increasing cutting speed. The roughness values decreased slightly and then increased again depending on the Z rO2 ratio. As the feed rates increased, a transition from ribbon chip type to the helical and saw-toothed forms was observed. It was also observed that the chip formation changed depending on the amount of ZrO2 in the composite structure. Keywords Machinability · Tool wear · Surface roughness · Chip form · ZrO2 · Al 1050
1 Introduction Aluminum alloys are a modern structural material used in various branches of the machinery industry. Aluminum is used in many areas due to its superior technical properties and low density [1]. It is the most widely used metal after steel, nowadays. Therefore, the machining of aluminum and aluminum matrix composites, such as ceramic-reinforced aluminum matrix composites, has become increasingly important. Machining of aluminum matrix composites can be much more difficult due to the addition of reinforcements such as SiC, A l2O3, ZrO2, TiB2, MgO, and B4C, which are much harder than the matrix material. There are various scientific studies in the literature regarding the machining Technical Editor: Jader Barbosa Jr., PhD. * Muharrem Pul [email protected] 1
Department of Electric and Energy, Kirikkale University, Kirikkale 71450, Turkey
of such particle-reinforced and aluminum-based composite materials. These studies generally address the machinability of the material based on parameters such as surface quality, tool wear, chip type, and cutting forces. Lin et al. [2] stated that cracks started on the outer surface of the chip due to the high shear stress
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