Effect of Feed Rate on Tool Wear in Milling of Al-4%Cu/B₄ C_p Composite

Abstract

The effect of feed rate on tool wear in milling of B₄C _p reinforced aluminum metal matrix composites (MMCs), produced by liquid phase sintering method, was investigated. Milling experiments on these composites were conducted with three different types of cementide carbide tools (uncoated, double coated (TiN + TiAlN) and triple coated (TiCN + Al₂O₃ + TiN)) for three different feed rates of 0.15 mm/z, 0.20 mm/z, and 0.25 mm/z. After milling experiments, an optical microscope was used to measure the magnitude of flank wear on the tools. Flank wear limit value, (V _B ) = 0.3 mm was selected as a reference value for comparison of these tools. On the other hand, tool wear mechanisms were examined with the help of a scanning electron microscope (SEM). Experimental results indicated that higher feed rates led to lower tool wear for all type of tools and coated tools exhibited better performance than uncoated tool with respect to the flank wear.

Keywords:

• Aluminum matrix
• Boron carbide
• Built-up-edge
• Coated tools
• Cutting speed
• Depth-of-cut
• Feed rate
• Flank wear
• Machinability
• Machining
• Metal-matrix composites
• Milling
• Powder metallurgy
• Sintering
• Wear