Advances in Science and Technology Received: 2020.08.10 Revised: 2020.09.20 Research Journal Accepted: 2020.10.15 Volume 14, Issue 4, December 2020, pages 262–272 Available online: 2020.11.01 https://doi.org/10.12913/22998624/127436

Effectiveness of in the Turning of Aluminium Composites

Paweł Karolczak1*, Marek Kołodziej1, Maciej Kowalski1

1 Department of Machine and Mechanical Engineering Technologies, Faculty of Mechanical Engineering, Wroclaw University of Technology and Science, Łukasiewicza 5, 50-371 Wrocław, Poland * Corresponding author’s e-mail: [email protected]

ABSTRACT Owing to their excellent strength-to-weight ratio aluminium composite materials are very readily used in the construction of means of transport. The parts made of such materials must be characterized by high reliability and workmanship. Hence, machining is the predominant method of manufacturing parts from composites. The problem with the turning, milling and drilling of ceramic-reinforced composites is the action of the rein- forcement, resulting in heavy wear of the blades and so in lower surface quality and dimensional-shape accuracy and higher manufacturing costs. A solution to this problem can involve the blades made of superhard materials or properly matched conditions of machining with sintered carbide blades. This paper presents the results of the turn- ing tests carried out on an aluminium composite material reinforced with long ceramic fibres. An uncoated sintered carbide is compared with a diamond coated blade and a polycrystalline diamond blade. Post-turning surface roughness and machining forces were selected as the main indicators of ability. The effect of the blades on the forming chips is shown and the higher resistance of the polycrystalline diamond blades to the abrasive action of the reinforcing fibres is confirmed by microscopic photographs. Besides the confirmation of the higher durability of the diamond blades, the conditions in which when using these blades one can achieve better machining effects than the ones achievable by the compared tools are defined. Moreover, it is shown that by properly matching the machining parameters and aiding machining with oil mist lubrication, it is possible to obtain excellent surface quality by means of carbide blades. The minimum quantity lubrication also increases the life of the blades.

Keywords: composite materials, superhard blade, surface roughness, cutting forces, chips.

INTRODUCTION material is even more important. The compos- ites based on metals satisfy the above-mentioned The current rapid development of means of requirements very well. Aluminium alloys, tita- transport concentrates on the introduction of in- nium alloys, copper alloys and magnesium al- novative structural materials. The main require- loys are most often used for the matrix of com- ments which must be met by such materials are posites. They are the most sought after materials very good strength properties at a low specific in various branches of the aviation industry, the weight. The properties should not change even at aerospace industry, the automotive industry and elevated temperatures. Moreover, the structural in military applications [20]. The composites in materials used in means of transport must be char- which an aluminium alloy is the matrix, are usu- acterized by high resistance to wear, high thermal ally reinforced with deposited particles or fibres. conductivity and low thermal expansion [19]. The Ceramic compounds, e.g. SiC and Al2O3, but also materials should not only meet the high require- graphite, are used as the reinforcing material [11]. ments, but also be relatively inexpensive. Today, The main important difference between the fibre- when industry pursues profitability and there is reinforced composites and the particle-reinforced an increasing emphasis on the environmental composites consists in the directionality of their protection, the selection of a proper structural properties. The material reinforced with particles

262 Advances in Science and Technology Research Journal Vol. 14(4), 2020 is isotropic, whereas the fibre-reinforced com- of the fibres or particles have the strongest effect posites are generally anisotropic. The matrix on the wear of polycrystalline diamond blades. endows the manufactured product with a shape The larger the amount and size of the reinforce- and protects its load-bearing reinforcement. For ment, the shorter the life of the blade [9]. Despite example, an addition of Al2O3 fibres strengthens the high resistance of diamond to abrasive wear, the microstructure and reduces the propagation of there is a limit speed above which the wear of matrix cracks in the areas between the fibres, thus diamond blades considerably increases. For ex- reducing the strains in the matrix and thus ample, diamond blades cannot be used effectively fatigue plasticity [7]. The most often used meth- when milling a composite reinforced with a 65% ods of producing ceramic-reinforced aluminium volumetric fraction of 10 μm SiC particles at a composites are: casting, powder metallurgy and speed of above 300 m/min [26]. An interesting spray deposition [23]. In the case of low shape- phenomenon was observed when machining an dimensional requirements, these advanced man- aluminium composite reinforced with short fibres ufacturing methods make it possible to produce and particles by means of tools made of respec- ultimately shaped and dimensioned composites tively uncoated carbide and coated carbide [24]. as machine components. On the other hand, be- Below the cutting speed of 250 m/min, cracks and cause of the high safety factors which must be spalls appeared, while above this speed the abra- met by means of transport, the quality require- sive wear of the flank increased consider- ments for the manufactured components are very ably. Other studies showed that the increase in the high. Therefore, manufacturing methods ensuring blade wear at higher machining parameters does the required dimensional tolerance and a proper not depend on whether the carbide tool is coated surface finish are indispensable in the production or not [2]. On the other hand, it was found that cycle [18]. Such a method is machining. during the machining of aluminium composites The machinability of the metal-matrix (in- reinforced with silicon carbide (SiC), tools with cluding aluminium-matrix) composites is the a CVD (chemical vapour deposition) diamond subject of extensive research. The greater hard- coating wear out quicker than polycrystalline dia- ness of the composite in comparison with the mond (PCD) inserts [1]. matrix material improves the surface layer forma- The machining parameters and the kind of tion conditions (less intensive build-up). Unfortu- tool material have a major bearing not only on nately, a few cases when reinforcement particles the tool life, but also on the machining proper- were pulled out of the composite surface, adher- ties (e.g. the cutting force) and machining effects ing to and building up on the , have (e.g. surface roughness). It was observed that at a been reported [15]. The ceramic reinforcement higher cutting speed, the matrix deforms less and has abrasive properties and poses a serious haz- the tool tears out and shears the reinforcement ard to cutting blades. Their abrasive wear is much more than pulls it out of the matrix. At the same faster than during the machining of aluminium al- time, as the cutting speed increases, the cutting loys [21]. Since the reinforcement is harder than force and the feed force decrease [8]. The de- the popular high-speed steels, the latter cannot be crease in the cutting force with increasing cutting used to machine the composites. In order to re- speed is ascribed to the higher temperature in the duce the cutting blade wear, the following tools shear , resulting in a reduction in the shear are suggested: polycrystalline diamond blades, strength of the machined material [22]. The qual- regular boron nitride blades and tungsten carbide ity of the surface (especially its roughness and blades [1]. Since these are very expensive tools, the absence of surface and near-surface defects) sintered carbide blades or ceramic blades can be is the most important machining effect for means used instead (at properly matched machining pa- of transport. Numerous studies indicate that using rameters)[10]. For machining the alumina fibre- polycrystalline diamond blades or regular boron reinforced or silicon carbide particle-reinforced nitride blades, one can obtain a less rough sur- aluminium composites, the tool life of a carbide face than the one obtained using carbide blades tool and that of a would be com- [17, 25]. At low feed rates, it is even possible to parable only for machining at low cutting speeds obtain mirror-like surfaces [4]. Even though the combined with a small depth of cut and a high depth of cut does not shorten tool life consider- rate of feed [6]. The volumetric amount of the ably, it adversely affects the surface quality. As reinforcement in the composite and the diameter the depth of cut increases, so does roughness and

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Table 1. Chemical composition of AlSi9Mg alloy [16] Element concentration, % Alloy designation Si Cu Mg Mn Fe Ti Zn Al AC-AlSi9Mg 9.5 <0.05 0.35 <0.1 <0.18 0.15 <0.07 rest

Table 2. Selected properties of AlSi9Mg alloy [16] Minimal properties Alloy designation Rm, MPa R0,2, MPa A50mm, % HB AC-AlSi9Mg 230 190 2 75 microcracks can appear in the surface layer [5]. the amount, size and kind of reinforcement and The research aimed at optimizing the machining properties of composite have a significant bearing of composites [12] shows that surface roughness on the effects of machining. Hence the authors’ is most affected by the rate of feed, followed by interest in this topic, and therefore research was the depth of cut, whereas the speed of cutting has undertaken. The aim of the research was an at- the smallest effect. The effect of cutting speed tempt to evaluate the effectiveness of the diamond is uncertain: it may not affect roughness [2] or blades application in a machining of ceramic-re- roughness may decrease with increasing speed, inforced aluminum composites and manufactured which is explained by the shorter time of contact at the Wroclaw University of Technology. This of the tool with the workpiece [22]. paper presents the results of this research. The literature survey shows that the com- posites reinforced with continuous fibres are still very difficult to machine [3] and the cutting tool TEST CONDITIONS must be harder than the reinforcement. This is why polycrystalline diamond (PCD), which ex- A metallic composite material based on an alu- hibits higher hardness, ensures a longer tool life. minium alloy (AlSi9Mg) matrix, reinforced with However, because of the high cost of PCD, other ceramic Saffil fibres was subjected to tests. The materials, such as sintered carbides and ceramic chemical composition of AlSi9Mg aluminium alloy compounds, are used for cutting tools. By prop- constituting the matrix is shown in Table 1 while its erly matching the machining parameters, one can selected properties are presented in Table 2. increase the effectiveness of each kind of blade. Saffil alumina fibres were used to reinforce Moreover, the technology of producing alumi- the matrix material. Table 3 shows the chemical num composites reinforced with ceramic fibers composition of the Saffil fibres while their select- has been developed in the Wroclaw University ed properties are shown in Table 4. One should of Science and Technology. These composites note the very high melting point of the Saffil fi- are different than the others known composites, bres and their high strength properties in compar- as they have specific properties. It is known that ison with the matrix.

Table 3. Chemical composition Saffil alumina fibres [13] Chemical composition, %

SAFFIL fibres Al2O3 - δ SiO2 Fe, Cr, Ni, Na, Mg, Ca, chlorides 96-97 3-4 trace amounts

Table 4. Selected properties of Saffil alumina fibres [13] Properties Tensile Young’s Melting Density, Mohs Diameter, Length. SAFFIL fibres strength modulus, point 0C , g/cm3 hardness μm mm , MPa GPa >20000C 2000 300 3.3 7 3 0.1-0.3

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Table 5. Selected properties of the tested material [13, 14] Properties

Tested material Rm, MPa R0,2, MPa HB α, 1/K 240-260 160-170 105-115 12-20

The main positive properties of the fibres aluminium composite material reinforced with reinforcing the tested material are [13]: stability Saffil fibres are presented in Table 5. A metallo- up to 1750°C, resistance to aggressive chemical graphic polished section of the tested material is compounds, small linear shrinkage, low density, shown in Figure 1 [13, 14]. low thermal conductivity, resistance to thermal The turning tests were carried out on a uni- shocks, high strength, high Young’s modulus, versal CNC TUR 560 MN lathe (Fig. 2a). The uniform fibre diameter, safety in use and large re- cutting tools recommended for aluminium alloy active surface area. machining were used in the tests. Owing to their The tested material was produced by squeeze novel tool materials and the improved design and casting in the Institute of Production Engineering geometry of the effector part, the tools can be used at Wrocław University of Technology. The com- to machine both soft materials, such aluminium posite was produced in two stages. First, a fitting alloys, as well as harder and stronger ones, such was made of Saffil fibres. Then the ceramic fitting as the tested composite material. The tests were was infiltrated with liquid metal [14]. carried out using STGCR 2020K–16 turning tool The tested material is characterized by higher and cutting inserts: TCGX16T304 – Al H10 un- hardness than that of the matrix material. The Al- coated sintered carbide insert, TCGX16T304 – Al Si9Mg aluminium alloy exhibited a hardness of 1810 diamond coated insert and TCMW 16T3 04F 74-80 HB. The composite material with 10% fi- – CD10 polycrystalline diamond insert. The ma- bre content, i.e. the material under investigation, chining parameters characteristic of both rough- exhibited a hardness of 106-124 HB depending on ing and finishing, i.e. vc = 150, 450 and 900 m/ the infiltration pressure used. Moreover, the ten- min; f = 0.08, 0.13 and 0.27 rpm, were applied. The sile strength (R ) of the tested material at room m depth of cut was ap = 0.5 mm. The machining tests temperature is higher than that of the aluminium were carried out respectively under dry machining matrix. This strength for the AlSi9Mg alloy is conditions and with the minimum quantity lubri- within the range: Rm = 200-210 MPa. The com- cation (MQL) of the cutting zone with oil mist. posite material reinforced with a 10% volumetric A MiniBooster MB II HDC dosing device made R Saffil fibre fraction exhibited strength m = 240 by Accu-Lube (Fig. 2b) was used to produce oil MPa for the lowest infiltration pressure used and mist. The oil mist was fed via two tubes onto the R strength m = 260 MPa for the three times higher tool flank and face. Fatty alcohol-based oil LB 500 pressure. The tested material did not exhibit a clear yield point under tension. This was due to the fact that the proportion of permanent strains relative to elastic strains would increase with load. Therefore, offset yield pointR 0,2 was determined. The composite with the volumetric fibre fraction of 10% exhibited a higher offset yield point than the matrix, amounting to 160-170 MPa in com- parison with 111-125 MPa for the AlSi9Mg alloy. The aluminium composite reinforced with a 10% Saffil fibre fraction is four times more resistant to abrasion than the matrix [13, 14]. The composite material also exhibits lower thermal expansion coefficient values versus tem- perature than the unreinforced matrix. Up to the temperature of 200°C coefficient α increases from 15 to 20 1/K, whereas below this temperature it Fig. 1. Metallographic polished decreases to about 12 1/K. The properties of the section of tested material

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a) b)

Fig. 2. Test stands a) CNC lathe, b) oil mist producing device a) b)

c)

Fig. 3. Test setup, from left: profilographometer, force gauge and oil mist feeding nozzles, sig- nal amplifier and oscilloscope, constituting the cutting force measuring circuit recommended for machining aluminium was used. performed in three places spaced at every 120° on The oil is nontoxic and environmentally safe. An- the perimeter of the turned surface. The measuring other advantage is that it does not leave stains or length amounted to 20 mm. The cutting forces were deposits on the machined surface. measured by means of a measuring circuit (Fig. 3) A Taylor Hobson Form Talysurf 120L pro- consisting of: a Kistler 9257A piezoelectric force filographometer (Fig. 3) was used to measure gauge, a signal amplifier type 5011 and a Tektronix roughness. Roughness measurements were Digital Phosphor Oscilloscope TDS 5054B.

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TEST RESULTS polycrystalline tools at feed rates up to 0.13 mm/ rev., one can obtain similar, and sometimes even Figures 4 and 5 show the results of roughness better surface roughness than the one obtained by measurements for the surface of the tested com- means of the coated and uncoated carbide blades. posite turned with carbide and diamond blades. However, for the feed rates used in high perfor- The basic roughness parameters most often used mance machining, better surface quality was ob- in industry, i.e. Ra and Rz, were selected for the tained after turning with uncoated carbide blades analysis. Consistently with the theory, the rough- and the best quality after machining with a dia- ness of the surface machined with each of the mond coated insert. The disadvantageous differ- tools depends on the feed rate. The values of the ence was reduced when machining was carried Ra and Rz parameters increase quadratically as out at the minimum quantity lubrication (MQL) the feed rate increases. In the feed rate range f of the cutting zone. Moreover, the use of oil mist = 0.08-0.13 mm/rev. roughness changes slightly, had a very beneficial effect on the surface turned but when the feed rate is increased to 0.27 mm/ with uncoated carbide blades. No such positive rev., it changes significantly. Comparing the tools effect of MQL was observed on the surfaces ma- used, one can notice that for dry turning with the chined with the polycrystalline diamond blades

Fig. 4. Surface roughness Ra versus feed rate f and cutting speed vc for Saf- fil fibre-reinforced aluminium composite material turned with respectively uncoat- ed carbide blade, diamond coated blade and polycrystalline diamond blade

Fig. 5. Surface roughness Rz versus feed rate f and cutting speed vc for Saf- fil fibre-reinforced aluminium composite material turned with respectively uncoat- ed carbide blade, diamond coated blade and polycrystalline diamond blade

267 Advances in Science and Technology Research Journal Vol. 14(4), 2020 and the diamond coated inserts, respectively. It with a polycrystalline diamond insert, it can be should be noted that when the diamond tools are concluded that consistently with the theory, the used, the scatter of roughness measurement re- differences between the values of the particular sults decreases considerably and higher machin- force components for dry turning are approxi- ing effect repeatability is obtained. It can also mately as follows: Ff = (0.3 - 0.4) * Fc and Fp be concluded that using either carbide blades or = (0.6 - 0.7) * Fc. Under the minimum quantity diamond blades, it is possible to obtain the com- lubrication conditions, the above-mentioned re- posite’s surface with roughness Ra below 1μm, lations are as follows: Ff = (0.3 - 0.4) * Fc and whereby it will not be necessary to subject com- Fp = (0.5 - 0.6) * Fc. Moreover, the variation in posite parts to abrasive machining, e.g. grinding. the cutting force depending on the rate of feed This obviously will be possible in the cases when is consistent with the theory. The effect of the no geometric composite surface structure with cutting speed is negligible. random tool marks is required. The use of oil mist for the cooling and lubri- While analysing the results of measure- cation of the cutting zone had a positive effect on ments of the cutting force components (Fig- the cutting force values. Under all the adopted ures 6-8) for the turning of the tested material turning conditions, except for the machining at

Fig. 6. Main cutting force component Fc (average value) versus feed rate f and cutting speed vc for the Saffil fibre-reinforced aluminium composite material turned with uncoated -car bide blade, diamond coated blade and polycrystalline diamond blade, respectively

Fig. 7. Cutting force feed component Ff (average value) versus feed rate f and cutting speed vc for the Saffil fibre-reinforced aluminium composite material turned with uncoated -car bide blade, diamond coated blade and polycrystalline diamond blade, respectively

268 Advances in Science and Technology Research Journal Vol. 14(4), 2020 the lowest feed rate and cutting speed, a reduc- higher pressures can be generated. It is also pos- tion in the cutting force was observed. The stron- sible that the absence of a chip breaker on the gest positive effect of MQL was obtained for the polycrystalline diamond plate, resulting in longer thrust force component Fp and feed force compo- chips, contributed to an increase in the vibrations nent Ff. The measured force values were lower by of the machine tool-holder-workpiece-tool sys- as much as 25%. The positive effect of MQL on tem, whereby the cutting forces increased signifi- main component Fc amounted to about 10%. cantly. At the feed rate of 0.27 mm/rev., the car- A comparison of the cutting force measure- bide blades would break chips and shorten their ment results for all the blades used shows that length, whereas during machining with diamond the polycrystalline diamond blade generates the plates, the chips were very long. No differences highest values of all the force components. This in chip length were observed at the feed rate of effect is visible for all the adopted machining pa- 0.08mm/rev. (Fig. 9). rameters, but it is particularly high for feed rate The polycrystalline diamond blades should f = 0.27mm/rev. The geometry and material of be more durable that the uncoated carbide blades. the blade can be the determining factors here. One can also assume that their abrasive wear will The diamond tool differs markedly in the shape be less intensive than that of diamond coated of its face. In addition, its material has lower blades, despite the stronger cutting forces. In or- impact strength than sintered carbide, whereby der to corroborate these assumptions, the face and

Fig. 8. Cutting force thrust component Fp (average value) versus feed rate f and cutting speed vc for the Saffil fibre-reinforced aluminium composite material turned with uncoated -car bide blade, diamond coated blade and polycrystalline diamond blade, respectively

Fig. 9. Chips obtained during turning of aluminium composite material with: a) diamond plate at feed rate f = 0.08 mm/rev., b) carbide plate at feed rate f = 0.08 mm/rev., c) diamond plate at feed rate f = 0.27 mm/rev. and d), e) carbide plate at feed rate f = 0.27 mm/rev

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Table 6. Photographs of the faces and flanks of the blades used in tests, taken after the experiment was completed Dry turning Turning with MQL Type Face Flank Face Flank

CD10

1810

H10

flank surfaces of the cutting plates were examined machining of aluminium alloys, such as the under microscope. The photographs of the blades matrix of the tested composite, were used. The after machining were taken under ZEISS Stereo tools were: uncoated carbide plates, diamond Discovery V.20 microscope. Because the number coated plates and polycrystalline diamond of carried out tests was too small and their dura- plates. The aim of the investigations was to find tion too short, it is not possible to fully assess the out if the use of much more expensive diamond wear of the tools, determine their wear over time tools offers wider machining possibilities and and unequivocally compare the degrees of blunt- improves the main effects of the machining of ing of all the blades (Table 6). Hence, only com- composites. Due to the abrasive action of their parative photographs, without measurements of reinforcement, ceramic-reinforced composite dulling criteria are presented. Nevertheless, sever- materials are difficult to machine, whereby the al conclusions can be drawn from the photographs blades used for their machining wear out faster. and the assumption concerning the likely longer The investigations showed that the necessity life of the diamond blades can be corroborated. of frequent blade replacement can be reduced After dry turning, all the blades show some wear, through the use of polycrystalline diamond but the uncoated carbide blade clearly shows the plates, since diamond wears out much slower. highest degree of wear. The wear is visible on both This reduction can certainly favourably affect its face and flank. The diamond coated insert also the efficiency of the machining of the tested shows considerable wear, which is heavier than on composites. An analysis pertaining to the re- the plate with a diamond insert. It should be noted sults of the measurements of the other tool cut- that the wear of all the blades is much smaller after ting ability indicators showed that: turning with the minimum quantity lubrication of − the surface after turning with each of the the cutting zone and the polycrystalline diamond tools is shaped consistently with the kine- blade shows only slight wear. matic-geometric mapping, no anomalies were observed; − for finishing feed rates (up to 0.13 mm/rev.) CONCLUSIONS lower values of the Ra and Rz roughness parameters were obtained for turning with The results of the turning tests carried out the polycrystalline diamond blade; on the aluminium composite material reinforced − for performance feed rate f = 0.27 mm/rev. with long Saffil ceramic fibres were presented. higher surface quality was obtained for ma- Generally available tools recommended for the chining with carbide inserts;

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