Investigation on the cutting quality characteristics of abrasive water jet machining of AA6061-B₄C-hBN hybrid metal matrix composites

ABSTRACT

Aluminum metal matrix composites (AMMCs) explicitly show better physical and mechanical properties as compared to aluminum alloys and results in a more preferred material for a wide range of applications. The addition of reinforcements embargo AMMCs employment to industry requirements by increasing order of machining complexity. However, it can be machined with a high order of surface integrity by nonconventional approaches like abrasive water jet machining. Hybrid aluminum alloy composites were reinforced by B₄C (5–15 vol%) and solid lubricant hBN (15 vol%) particles and fabricated using a liquid metallurgy route. This research article deals with the experimental investigation on the effect of process parameters such as mesh size, abrasive flow rate, water pressure and work traverse speed of abrasive water jet machining on hybrid AA6061-B₄C-hBN composites. Water jet pressure and traverse speed have been proved to be the most significant parameters which influenced the responses like kerf taper angle and surface roughness. Increase in reinforcement particles affects both the kerf taper angle and surface roughness. SEM images of the machined surface show that cutting wear mechanism was largely operating in material removal.

KEYWORDS:

• AA6061
• boron carbide
• composite
• hardness
• kerf
• roughness
• stir
• tensile
• water jet

Acknowledgement

The authors are grateful to The Department of Industrial Engineering and The Department of Manufacturing Engineering, CEG Campus, Anna University Chennai, India for extending the facilities to assist in the conduction of this investigation.

Additional information

Funding

The authors acknowledge the financial support for the Research Consumables rendered by DST PURSE Phase II.