Influence of Machining Parameter on Tool Life While Machining Hybrid Metal Matrix Composites

Abstract

A metal matrix composite constitutes a continuous metallic matrix and a discontinuous phase known as reinforcement. The hybrid metal matrix composites (Hmmcs) have been used to manufacture drive shafts, disc brake rotors, brake drums, connecting rods pistons, engine block cylinder liners for automotive and rail vehicle applications. The Hmmcs castings of diameter 120 mm and length 300 mm were prepared through sand mould technique following stir casting methodology. The cast components further subjected to evaluation of physical properties and machining tests using two grades of coated inserts and PCD inserts. The experiments were carried out following ISO 3685 standards. The coating thickness of the TiN coated and TiAlN coated inserts were measured using Kalo testing method; the results of the test show that the interface of the substrate and coating was free from the porosity, and the coating thickness of TiN coating was 4.84 microns and TiAlN coating was measured 4.6 microns. The results of the experiments show that performance of the PCD insert was better than coated inserts at 0.1 mm/rev feed; however at 0.2 mm/revolution feed PCD insert failed by micro chipping of cutting edge while machining Hmmcs. When TiAlN coated inserts were used to machine Hmmcs the coated inserts failed by gradual wear and BUE formation.