Machinability of Metal Matrix Composites Reinforced by 3-D Network Structure
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Machinability of Metal Matrix Composites Reinforced by 3-D Network Structure Shouren Wang & Haoran Geng & Bo Song & Yingzi Wang
Received: 4 June 2006 / Accepted: 30 August 2006 / Published online: 26 October 2006 # Springer Science + Business Media B.V. 2006
Abstract Metal matrix composites reinforced by three-dimensional (3-D) continuous network structure reinforcement (3DCNRMMC) are difficult to machine due to serious tool wear and poor surface roughness caused by the brittle and hard reinforcement which interpenetrate into ductile matrix. In order to achieve the approach of low cost of 3DCNRMMC, the machinability of it needs to be understood. The influences of three cutting parameters and volume fraction of reinforcement on cutting force were analyzed in detail. The results indicate that: (1) Due to the brittle phase(s) introduced into ductile matrix of composites, there is a large fluctuation of cutting force causing deterioration of machinability. The fluctuation ranges of cutting forces, initially increase rapidly with the increase of volume fraction of reinforcement and then decrease finally, are largest at the range of the volume fraction of 55–65%; (2) The influence of cutting parameters on cutting force is obvious. With the increases of cutting speed, cutting force decreases gradually unless cutting speed exceeds the value of 209 m/min. Cutting forces increase with increasing feed rate and depth of cut; (3) Owing to the large fluctuation of cutting force, there were some cratered surfaces caused by Si3N4 reinforcement pulling-out and flaking-off. Some brittle phase protruding from the machined surface caused the deterioration of machined surface. Key words metal matrix composites . machinability . cutting force . machined surface topography
1 Introduction Metal matrix composites reinforced by three-dimensional (3-D) continuous network structure reinforcement (3DCNRMMC) exhibit outstanding performance and excellent mechanical properties [1, 2]. 3DCNRMMC are being used increasingly in aerospace, S. Wang (*) : B. Song School of Mechanical Engineering, Jinan University, Jinan 250022, China e-mail: [email protected] H. Geng : Y. Wang School of Material Science, Jinan University, Jinan 250022, China
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Appl Compos Mater (2006) 13: 385–395
Figure 1 Topography of: a reticulated Si3N4 ceramics perform; b 3DCNRMMC.
automobile, military and shipping industries [3, 4]. However, the machinability of 3DCNRMMC is preventing them from being used in widespread industries. The high cost associated with the machining resist their development due to the poor surface finish of workpiece and excessive wear on the cutting tools. Although machining of 3DCNRMMC has a large difficulty and efforts have been made to manufacture it by near-net shape technique, the final finishing of products may still be needed for the final designed dimensions and required surface finish [4, 5]. Hence, poor machinability of 3DCNRMMC has become the bottle-neck for the development of composites and the problem must be solved via some kinds of
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