Alokesh Pramanik

Machining and tool wear mechanisms during machining titanium alloys

This paper investigates the machining mechanism of titanium alloys and analyses those understandings systematically to give a solid understanding with latest developments on machining of titanium alloys. The chip formation mechanism and wear of different cutting tools have been analyzed thoroughly based on the available literature. It is found that the deformation mechanism during machining of titanium alloys is complex and it takes place through several processes. Abrasion, attrition, diffusion–dissolution, thermal crack and plastic deformation are main tool wear mechanisms.

Effects of reinforcement on wear resistance of aluminum matrix composites

The effect of reinforcement on the wear mechanism of metal matrix composites (MMCs) was investigated by considering different parameters, such as sliding distance (6 km), pressure (0.14–1.1 MPa) and sliding speed (230–1480 r/min). The wear mechanisms of an MMC and the corresponding matrix material under similar experimental conditions were compared on a pin-on-disc wear machine. The pins were made of 6061 aluminum matrix alloy and 6061 aluminum matrix composite reinforced with 10% Al2O3 (volume fraciton) particles (6–18 μm). The disc was made of steel. The major findings are as follows: the MMC shows much higher wear resistance than the corresponding matrix material; unlike that of matrix material, the wear of MMC is very much linear and possible to predict easily; the wear mechanism is similar for both materials other than the three-body abrasion in the case of MMC; the reinforced particles resist the abrasion and restrict the deformation of MMCs which causes high resistance to wear. These results reveal the roles of the reinforcement particles on the wear resistance of MMCs and provide a useful guide for a better control of their wear.

Machining of titanium alloy (Ti-6Al-4V) - theory to application

This article correlates laboratory-based understanding in machining of titanium alloys with the industry based outputs and finds possible solutions to improve machining efficiency of titanium alloy Ti-6Al-4V. The machining outputs are explained based on different aspects of chip formation mechanism and practical issues faced by industries during titanium machining. This study also analyzed and linked the methods that effectively improve the machinability of titanium alloys. It is found that the deformation mechanism during machining of titanium alloys is complex and causes basic challenges, such as sawtooth chips, high temperature, high stress on cutting tool, high tool wear and undercut parts. These challenges are correlated and affected by each other. Sawtooth chips cause variation in cutting forces which results in high cyclic stress on cutting tools. On the other hand, low thermal conductivity of titanium alloy causes high temperature. These cause a favorable environment for high tool wear. Thus, improvements in machining titanium alloy depend mainly on overcoming the complexities associated with the inherent properties of this alloy. Vibration analysis kit, high pressure coolant, cryogenic cooling, thermally enhanced machining, hybrid machining and, use of high conductive cutting tool and tool holders improve the machinability of titanium alloy.

Electrical Discharge Machining of MMCs Reinforced with Very Small Particles

This paper investigates material removal rate (MRR), kerf width, surface finish, and electrode wire wear for different pule-on-times as well as wire tensions during EDM of 6061 aluminum alloy reinforced with 10 vol % 700 nm SiCp MMC. Effects of pulse-on-time on output variables at lower and higher wire tensions were investigated. Similarly, effects of the wire tensions on output variables at shorter and longer pulse-on-times were also investigated. Longer pule-on-time increases the MRR though the higher wire tension reduces the MMR. The effect of wire tension on MRR is much more significant at longer pule-on-time compare to that at shorter pule-on-time. There is an optimum pule-on-time for which best surface finish is achieved. The surface finish deteriorates when the pulse-on-time is higher or lower than the optimum pule-on-time. With the rise of tension in wire, the surface roughness increases and decreases at shorter and longer pule-on-times, respectively. The machined surface contains solidified molten material, splash of materials, and blisters. Generation of the tapered slot with higher kerf width at the top indicates the wear of wire electrode. Significant variation of the electrode wire diameter was due to coating of the matrix, wear, and clogging of small reinforced particles in the electrode gap.

Electrical discharge machining of 6061 aluminium alloy

The wire electrical discharge machining (EDM) of 6061 aluminium alloy in terms of material removal rate, kerf/slit width, surface finish and wear of electrode wire for different pulse on time and wire tension was studied. Eight experiments were carried out in a wire EDM machine by varying pulse on time and wire tension. It is found that the material removal rate increases with the increase of pulse on time though the wire tension does not affect the material removal rate. It seems that the higher wire tension facilitates steady machining process, which generates low wear in wire electrode and better surface finish. The surface roughness does not change notably with the variation of pulse on time. The appearance of the machined surfaces is very similar under all the machining conditions. The machined surface contains solidified molten material, splash of materials and blisters. The increase of the pulse on time increases the wear of wire electrode due to the increase of heat input. The wear of wire electrode generates tapered slot which has higher kerf width at top side than that at bottom side. The higher electrode wear introduces higher taper.

Weldability of duplex stainless steel

Duplex stainless steels (DSSs) have many advantages due to the unique structural combination of ferrite and austenite grains. The structural change of these materials is very complex during welding, and it deteriorates the functional properties. This research investigates different welding processes such as laser beam, resistance, tungsten inert gas, friction stir, submerged arc, and plasma arc weldings considering the research available in the literature. The welding mechanism, change of material structure, and control parameters have been analyzed for every welding process. This analysis clearly shows that DSS melts in all most all welding processes, but the thermal cycle and maximum heat input are different. This difference affects the resulting structure and functional properties of the weld significantly.

Fabrication of Nano-Particle Reinforced Metal Matrix Composites

Nanoparticle reinforced metal matrix possess much better mechanical properties over microparticle reinforced metal matrix composites as well as corresponding monolithic matrix materials. However, the fabrication methods of nanoparticle reinforced metal matrix composites are complex and expensive. This paper investigates and discusses the mechanisms of all the fabrication process, such as powder metallurgy, liquid metallurgy, compocasting and hybrid methods, available in the literature. This gives an insight on challenges associated with different processes and ways to improve the fabrication processes. It is found that modified traditional fabrication processes are mainly applied for these materials. The main problem is to achieve reasonably uniform distribution of nanoparticle reinforcement in the methods other than mechanical alloying when the volume or weight percent of reinforcement is higher (> 1%).

Effect of reinforced particle size on wire EDM of MMCs

This paper investigates the effect of the size of reinforced particles on wire electrical discharge machining (EDM) of metal matrix composites (MMCs) in terms of material removal rate (MRR), surface integrity and wear of wire electrodes (WEs). It was found that larger particles significantly reduced the MRR, as they were better able to protect the matrix material from EDM sparks compared to smaller particles. The machined surfaces were full of solidified melted matrix, splashes of melted material, cavities and blisters, which are not significantly affected by particle size. Spattering and splashing might have contributed to the transfer of materials between the WE and the MMCs. The diameter of the WE was reduced nonlinearly with the increased size of the reinforced particles after machining. The smallest reduction in electrode diameter occurred in the unreinforced matrix material.

Failure Mechanisms of Nanoparticle Reinforced Metal Matrix Composite

The quest for the advanced functional material of superior functionality for advanced structure is being driven in various fronts of engineering materials. One of such front is metal matrix composite (MMC) which has already been proven as one of the most productive field in that respect. With the advance of technology, now it is possible to reinforce the MMCs with nanosized particles compared to conventional micron-sized ones. However, the addition of nanoparticle in the MMC to improve its mechanical properties is not unconditional. To achieve positive gain by adding nanoparticles in the MMCs, all the influencing factors should be taken into consideration. The present paper reviews the failure mechanisms of nanoparticles reinforced MMCs in light of its strengthening mechanisms.

Machining of particulate-reinforced metal matrix composites

The presence of hard reinforce particles in two phases materials, such as metal matrix composites (MMCs), introduces additional effects, such as tool–particle interactions, localised plastic deformation of matrix material, possible crack generation in the shear plane etc., over the monolithic material during machining. These change the force, residual stress, machined surface profile generation, chip formation and tool wear mechanisms. Additional plastic deformation in the matrix material causes compressive residual stress in the machined surface, brittle chips and improved chip disposability. Possible crack formation in the shear plane is responsible for low machining force and strength and higher chip disposability. Tool–particle interactions are responsible for higher tool wear and voids/cavities in the machined surface. This chapter presents the effects of reinforcement particles on surface integrity and chip formation in MMCs. The modelling of cutting is also discussed. Finally, tool wear mechanisms are described.