Influence of turning parameters on the machinability of Al6061/ZrB2 & ZrC hybrid in-situ Aluminium Matrix Composite

ABSTRACT

This paper presents the machining characteristics of AA6061/(0–9 wt%) ZrB₂+ ZrC aluminium metal matrix composites using polycrystalline Diamond(PCD). In the present investigation, AMCs were fabricated by in situ reactions between K₂ZrF₆, KBF₄ and SiC particles. The electric stir casting furnace was used to fabricate the AMCs under a controlled environment. X-ray diffraction patterns (XRD) and field emission scanning electron microscope (FESEM) were used to ascertain the formation of ZrB₂ and ZrC particles in the AMCs. FESEM micrographs confirmed the uniform distribution of ZrB₂ and ZrC particulates along with good interfacial bonding with matrix aluminium alloy. The effect of varying wt% of ZrB₂+ ZrC along with cutting speed, feed and depth of cut on machining forces and surface roughness were analysed. FESEM was used to study the morphology of cutting tool, machined surface and chip formation. It was observed that cutting forces reduce with increase in cutting speed due to decrease in built-up edge (BUE) formation and deprivation of dislocation density. The tool wear increased with increase in cutting speed, depth of cut and ZrB₂ + ZrC content due to the increase in abrasive action of ceramic particles and reduction of stable BUE.

KEYWORDS:

• FESEM
• XRD
• BUE
• AMC and ZrB2 -ZrC

Acknowledgments

The authors are grateful to Centre for Research in Design and Manufacturing Engineering (CRDM) at Karunya Institute of Technology & Sciences, Coimbatore and The South India Textile Research Association (SITRA) for providing the facilities to executing this research work.

Disclosure statement

No potential conflict of interest was reported by the author(s).

Data availability statement

There are no data for this paper.

Additional information

Notes on contributors

S Rajesh Ruban

Dr. S. Rajesh Ruban received his doctoral degree from Karunya Institute of Technology and Sciences,Coimbatore, India. He is presently working as Assistant Professor in Department of Mechanical Engineering. Karunya Institute of Technology and Sciences. His research interest Includes metal matrix composite, stir casting and wear. He has published 20 technical articles in peer-reviewed international journals

K Leo Dev Wins

Dr. K. Leo Dev Wins started his career in 2000 as Lecturer in Mechanical Engineering at Karunya Institute of Technology and Sciences. Coimbatore.   He has 20 years of teaching and research experience   at undergraduate and postgraduate levels. His broad areas of interest include Engineering Drawing, Machining with minimal cutting fluid application, Metallic coatings, Machining of composite materials, Machining of hardened alloys, Industrial Engineering and Machine vision systems. He has published over 50 research papers in various international / national journals and conferences.

J David Raja Selvam

Dr. J. David Raja Selvam received his doctoral degree from Karunya University, Coimbatore, India. He is presently working as Assistant Professor in Department of Mechanical Engineering. karunya University. His research interest includes metal matrix composite, stir casting and wear. He has published 30 technical articles in peer-reviewed international journals.

Rajakumar S Rai

Rajakumar S. Rai is an Assistant Professor in the Department of Mechanical Engineering at Karunya Institute of Technology and Sciences (KITS), Coimbatore, India. He obtained his B.E. degree in Mechanical Engineering from Bharathiar University, Coimbatore, India, in 2001; M.E. degree in Computer Aided Design (CAD), from University of Madras, Chennai, India, in 2002; and Ph.D. in Mechanical Engineering from Anna University, Chennai, India in 2016. He has more than 18 years of teaching experience. He has published research articles in refereed journals and conference proceedings. His research interests include Composite materials and Additive manufacturing.