Showing papers in "Materials and Manufacturing Processes in 2016"
TL;DR: In this article, the authors present an up-to-date review of progress and benefits of different routes for fabrication and machining of composites and conclude that polycrystalline tools and diamond-coated tools are best suitable for various conventional machining operations.
Abstract: Intrinsically smart, metal matrix composites (MMCs) are lightweight and high-performance materials having ever expanding industrial applications. The structural and the functional properties of these materials can be altered as per the industrial demands. The process technologies indulged in fabrication and machining of these materials attract the researchers and industrial community. Hybrid electric discharge machining is a promising and the most reliable nonconventional machining process for MMCs. It exhibits higher competence for machining complex shapes with greater accuracy. This paper presents an up-to-date review of progress and benefits of different routes for fabrication and machining of composites. It reports certain practical analysis and research findings including various issues on fabrication and machining of MMCs. It is concluded that polycrystalline tools and diamond-coated tools are best suitable for various conventional machining operations. High speed, small depth of cut and low feed ra...
251 citations
TL;DR: Copper and aluminum materials are extensively used in different industries because of its great conductivities and corrosion resistant nature as discussed by the authors. And it is important to join dissimilar materials such as c....
Abstract: Copper and aluminum materials are extensively used in different industries because of its great conductivities and corrosion resistant nature. It is important to join dissimilar materials such as c...
206 citations
TL;DR: In this paper, the effect of part deposition orientation on surface finish and dimensional accuracy of FDM parts is studied and the part selected for this study is designed in such a way that different primitive geometric features at different directions are present.
Abstract: Fused deposition modeling (FDM) process is an additive manufacturing technology where objects are manufactured in layers. In the present days, FDM is commercially used to build prototypes, functional components; however, these parts majorly suffer from poor surface quality and dimensional accuracy even for basic part geometries. In the present paper, first the effect of part deposition orientation on surface finish and dimensional accuracy of FDM parts are studied. The part selected for this study is designed in such a way that different primitive geometric features at different directions are present. The parts are built at different orientations (0°, 15°, 30°, 45°, 60°, 75°, 90°) using acrylonitrile butadiene styrene P430 material, and surface finish and dimensional accuracy are measured at different surfaces. Next, the FDM parts are postprocessed by cold vapor treatment of dimethylketone (acetone) and improvement in surface finish and change in dimensional accuracy are investigated. The results show th...
178 citations
TL;DR: In this article, a defect free dissimilar copper-aluminum friction stir welding was achieved by tilt angles 2°, 3°, and 4° with an interval of 1°, while other parameters such as rotational speed, welding speed, tool pin offset, and workpiece material position were kept constant.
Abstract: In the present investigation, dissimilar materials such as electrolytic tough pitch copper, and aluminum 6061-T651 were welded by friction stir welding technology. Effects of tool tilt angle on the mechanical and metallurgical properties were studied experimentally for dissimilar material systems. In the present study, the tool tilt angle was varied from 0° to 4° with an interval of 1°, while the other parameters such as rotational speed, welding speed, tool pin offset, and workpiece material position were kept constant. Macrostructure analysis, tensile test, macro hardness measurement, scanning electron microscopy, and energy dispersive x-ray spectrographic tests were performed to evaluate the weld properties of dissimilar copper–aluminum joints. The results revealed that a defect free dissimilar copper–aluminum friction stir welding was achieved by tilt angles 2°, 3°, and 4°. The maximum tensile strength was reported to be 117 MPa and the macro hardness was reported to be 181 VH (in the nugget zone) at ...
140 citations
TL;DR: In this paper, an application of response surface methodology (RSM) and particle swarm optimization (PSO) technique for optimizing the machining factors in turning of titanium (Grade-II) alloy using cubic boron nitride insert tool under minimum quantity lubricant (MQL) environment.
Abstract: The present paper depicts an application of response surface methodology (RSM) and particle swarm optimization (PSO) technique for optimizing the machining factors in turning of titanium (Grade-II) alloy using cubic boron nitride insert tool under minimum quantity lubricant (MQL) environment. The three machining factors, i.e., cutting speed (Vc), feed rate (f) and side cutting edge angle (approach angle π), are designed as three factors by using RSM design, which is withal subject to several constraints including tangential force (Fc), tool wear (VBmax), surface roughness (Ra) and tool-chip contact length (L). The multiple regression technique was used to establish the interaction between input parameters and given responses. Moreover, the results have been presented and optimized process parameters are acquired through multi-response optimization via desirability function as well as the PSO technique. The lower values of Vc (200 m/min), f (0.10 mm/rev) and higher values of ϕ (90°) are the optimum machini...
136 citations
TL;DR: In this paper, the basic material removal phenomenon of ultrasonic machining (USM) and conventional diamond grinding amalgamates together and results in higher material removal rate (MRR), improved hole accuracy with superior surface finish.
Abstract: Rotary ultrasonic machining (RUM) is a mechanical type of nontraditional hybrid machining process that has been utilized potentially to machine a wide range of latest and difficult-to-machine materials, including ductile, hard and brittle, ceramics, composites, etc. In RUM, the basic material removal phenomenon of ultrasonic machining (USM) and conventional diamond grinding amalgamates together and results in higher material removal rate (MRR), improved hole accuracy with superior surface finish. In the current article, several investigations carried out in the domain of RUM for enormous materials have been critically reviewed and reported. It also highlights several experimental and theoretical ensues of RUM to improve the process outcomes and it is reported that process performance can be substantially improved by making the right selection of machine, diamond tooling, material and operating parameters. In recent years, various investigators have explored umpteen ways to enhance the RUM process performa...
123 citations
TL;DR: In this article, the machinability of nickel-based superalloys using abrasive water jet machining process was investigated. And the machining studies were carried out with three different parameters such as water jet pressure, traverse speed of jet nozzle and standoff distance at three different levels.
Abstract: This paper deals with the machinability of nickel-based superalloys using abrasive water jet machining process. The machining studies were carried out with three different parameters such as water jet pressure, traverse speed of jet nozzle, and standoff distance at three different levels. The performances of the process parameters are evaluated by measuring difference in kerf width, kerf wall inclination, and material removal rate (MRR). Further, the surface morphology and material removal mechanisms are analyzed through scanning electron microscope (SEM) images. It is found that water jet pressure is the most influencing factor related to surface morphology and surface quality.
106 citations
TL;DR: In this paper, the response of a duplex stainless steel alloy to processing by selective laser melting with varying process conditions is evaluated in the current research, and it is shown that the complete cycle starting from duplex powders, consolidating into 3D forms by selecting laser melting and then post-process heat treatment to bring the microstructures back to duplex forms is feasible.
Abstract: Selective laser melting gained substantial momentum in the recent past and quite a few alloy systems have been researched and made available for commercial use; titanium, aluminum, stainless and tool steels, cobalt chrome, and Inconel being the most popular examples. Despite the application potential, and the successful processing of powder forms by traditional powder metallurgy methods, selective laser melting of duplex stainless steels was not attempted so far. The response of a duplex stainless steel alloy to processing by selective laser melting with varying process conditions is evaluated in the current research. Experimental results ascertained that the complete cycle starting from duplex powders, consolidating into 3D forms by selective laser melting and then post-process heat treatment to bring the microstructures back to duplex forms is feasible. Within the current experimental domain, the multi-layer samples are close to 90% density and showed a maximum dimensional variation of 2–3%, while the a...
101 citations
TL;DR: In this paper, a hybrid natural fiber composite with filler has been developed with and without filler materials as reinforcement to improve the quality and property of the component materials based on the requirements and its applications.
Abstract: The filler materials are reinforced along with natural fibers in the composite to improve the quality and property of the component materials based on the requirements and its applications. In this paper, hybrid natural fiber composites were developed with and without filler materials as reinforcement. The developed hybrid natural fiber composites are machined using abrasive water jet cutting process with three different cutting parameters. The influences of cutting parameters are evaluated with respect to the kerf wall inclination, material removal rate, and surface roughness. The surface morphology was also studied to infer the basic mechanism involved during composite machining. The hybrid fiber composite with filler has proved that it can produce good engineering component without delamination and fiber pullouts during machining.
96 citations
TL;DR: In this paper, three important aspects of surface integrity of a machined part, including surface roughness, micro-hardness, and residual stresses, were analyzed for their variations with the cutting parameters.
Abstract: Control of surface integrity is a vital consideration in the machining of components subjected to fatigue loading, for example, critical components of aerospace engines. In this research, three important aspects of surface integrity of a machined part—surface roughness, micro-hardness, and residual stresses—were analyzed for their variations with the cutting parameters. Finish milling of super alloy GH4169/Inconel 718 was carried out using coated cemented carbide and whisker-reinforced coated ceramic inserts. All of the three machining parameters—cutting speed, feed rate, and depth of cut—were found to have a substantial effect on the surface integrity of the finished part. Although different cutting parameters gave different effects for the two types of cutting inserts, overall better surface integrity was obtained at minimum cutting feed and medium cutting speed and depth of cut value. Moreover, carbide inserts produced better surface integrity of the finished part, whereas ceramic inserts generated ver...
94 citations
TL;DR: In this paper, the influence of wire-electrical discharge machining (WEDM) process parameters on different performance measures during machining of Nimonic C-263 superalloy was investigated.
Abstract: In recent years, wire-electrical discharge machining (WEDM) has gained popularity in the industry due to its capability to generate complicated shapes in exotic materials, irrespective of their hardness. Conventional machining of Nimonic C-263 superalloy is an extremely difficult and costly process due to its high hardness and tool wear rate. The present research work investigates the influence of the WEDM process parameters on different performance measures during machining of Nimonic C-263 superalloy. A mathematical model for all four important performance measures, namely, cutting rate, surface roughness, spark gap, and wire wear ratio, was developed and the responses were used for studying the interrelationship between performance measures and process parameters. The optimal settings of operating conditions were predicted using desirability function. The effectiveness of multicut strategy was also investigated in the article.
TL;DR: In this article, an experimental investigation has been performed in order to study the effect of SiC microparticle suspended dielectric on machining Ti-6Al-4V with tungsten carbide electrode.
Abstract: Microelectric discharge milling is one of the variants of microelectric discharge machining process which acquire the attention of researchers due to its unique ability to produce microchannels and three-dimensional structures in difficult-to-machine materials like titanium. In the present work, an experimental investigation has been performed in order to study the effect of SiC microparticle suspended dielectric on machining Ti-6Al-4V with tungsten carbide electrode. The effects of major electric discharge milling process parameters—voltage, capacitance, and powder concentration in dielectric—on responses—viz., material removal rate (MRR) and tool wear rate (TWR)—were studied. Experiments were designed and performed based on response surface methodology (RSM)-Box–Behnken statistical design and the significance of in put parameters were identified with the help of analysis of variance. From the results, it is recommended to use powder concentration of 5 g/L, capacitance of 0.1 µF, and voltage of 115 V for...
TL;DR: In this paper, the effect of FSP process parameters such as tool rotation, traverse speed and tool tilt on resulting grain size, microstructure and superplastic behavior of high-strength thick Al-Zn-Mg-Cu alloy is reported.
Abstract: Friction stir processing (FSP) is a novel technique for refining the microstructure. In this study, the effect of FSP process parameters such as tool rotation, traverse speed and tool tilt on resulting grain size, microstructure and superplastic behavior of high-strength thick Al-Zn-Mg-Cu alloy is reported. The microstructure examination of the stir zone (SZ) was performed by optical as well as scanning electron microscope. Microstructure variation attributed to different process parameters is reflected in the SZ. It is observed that grain size increases with increasing tool rotation speed, and decreases with increasing traverse speed. However, tool tilt has no significant effect on grain size. Moreover, at higher tool tilt distorted grains were observed in microscopic images. The highest average value of hardness in the SZ is obtained for low heat input value corresponding to higher tool rotation and traverse speed. In this study, hardness has shown no dependency on the grain size of the SZ due to the st...
TL;DR: In this paper, a review summarizes the state of the art of the design, preparation techniques of durable super-hydrophobic coatings with contact angles (CAs) > 150° and sliding angles (SAs) < 10°.
Abstract: Superhydrophobic coatings with contact angles (CAs) > 150° and sliding angles (SAs) < 10° have become the focus of research and industrial development studies for water repellency applications. Furthermore, superhydrophobic coatings have shown to reduce ice adhesion by means of their low surface energy chemistry and nano/micro roughness. Superhydrophobicity can be achieved by combining the chemistry and the roughness of the surface, inspired by the lotus leaf composition and structure. Durability enhancement of superhydrophobic surfaces is a critical issue for commercial and industrial applications. Consequently, the use of superhydrophobic surfaces in practical applications is limited due to their poor mechanical abrasion resistance and hostile environmental conditions. Covalent bonding of the micro/nano particles to the binder material was identified as essential for durability enhancement. This review summarizes the state of the art of the design, preparation techniques of durable superhydrophobic coat...
TL;DR: In this paper, a series of coatings for drilling low and medium carbon alloyed steels are presented, along with their performance, and validation tests were carried out on steel 42CrMo4.
Abstract: Cutting tool performance is mainly characterized by material substrate, cutting edge geometry, and coating, and also by a good choice of the cutting parameters, mainly cutting speed, depth of cut, and feed. In drilling a good choice of substrate/coating can reduce production costs per hole cut by 50%. Coatings evolution has gone from monolayer to nanostructured and/or nanometric-scale multilayer coatings. These are used because of their high hardness, good corrosion and oxidation resistance, and thermal stability. Cutting edge preparation on the one hand and droplet elimination after the coating process on the other are important issues for reaching a good tool/coating performance, being a key issue. In this article a series of coatings for drilling low and medium carbon alloyed steels are presented, along with their performance. Validation tests were carried out on steel 42CrMo4, very often used in the automotive sector. Seven coatings were tested, including AlCrSiN, µAlTiN, TiAlCrN, AlTiCrN, AlCrN, AlTi...
TL;DR: In this paper, a hybrid machining process which combines laser and micro-EDM processes for drilling microholes in advanced engineering materials such as Nickel-Titanium (Ni-Ti)-based shape memory alloy was proposed.
Abstract: Micro-electrical discharge machining (EDM) is a slow process as compared to laser machining, on the contrary laser machining lacks good surface quality. To overcome the drawbacks of both these processes, this paper suggests a hybrid machining process which combines laser and micro-EDM processes for drilling microholes in advanced engineering materials such as Nickel–Titanium (Ni–Ti)-based shape memory alloy. To achieve the objective of the suggested hybrid process, pilot holes are drilled with laser machine and rimmed out by micro-EDM drilling. The suggested process requires investigation of various combinations of micro-EDM drilling process conditions to obtain optimum machining parameters for the hybrid process. It has been found that the proposed hybrid machining process resulted in 50–65% reduction in machining time without affecting the quality of microholes as compared to the standard micro-EDM process.
TL;DR: In this article, a hard layer of tungsten and copper mixture is created at selected area of aluminum surface using W-Cu powder metallurgical green compact tool and masking technique in die-sinking electric discharge machining.
Abstract: This paper introduces selective modification of surface by electric discharge machining process and its parametric optimization A hard layer of tungsten and copper mixture is created at selected area of aluminum surface The process is done using W–Cu powder metallurgical green compact tool and masking technique in die-sinking electric discharge machining (EDM) The modified surface is evaluated by the performance measures such as tool wear rate, material transfer rate, surface roughness, and edge deviation from the pre-defined boundary line of deposited layer by analysis of variance using Taguchi design of experiment Minimum surface roughness of 45 µm and minimum edge deviation of 3729 µm is achieved The hardness of the surface layer is increased more than three times of base metal Overall effects of parameters are also analyzed considering multiple performance criteria using overall evaluation criteria The modified surface is characterized using scanning electron microscopy and energy dispersive
TL;DR: In this paper, the effect of pulse duration on aspect ratio of glass material machined by ECDM was investigated experimentally to achieve better control on the quality characteristics of machining depth, surface damage, aspect ratio, and tool wear.
Abstract: Electrochemical discharge machining (ECDM) has proven its usefulness for micro-machining of hard, brittle, and nonconductive materials. Pulse duration is one of the most important process parameters in ECDM. The present article investigates the effect of pulse duration on aspect ratio of glass material machined by ECDM. An effective range of pulse duration was identified experimentally to achieve better control on the quality characteristics. The quality characteristics measured were machining depth, surface damage, aspect ratio, and tool wear. Results reveal that a limited range of pulse duration affects the quality characteristics leading to high aspect ratio. Further, values of process parameters for high aspect ratio of holes were identified. Effect of applied voltage on tool wear was also investigated.
TL;DR: In this paper, an ultrasonic cavitation-assisted casting process was used to fabricate the aluminum alloy-nano boron carbide metal matrix nanocomposites.
Abstract: In this research work, ultrasonic cavitation-assisted casting process was used to fabricate the aluminum alloy-nano boron carbide metal matrix nanocomposites. The optical microscopy results revealed the refined matrix grains in the microstructure of the aluminum alloy-nano boron carbide composites. Boron carbide nanoparticles were uniformly distributed in the aluminum alloy matrix, which can be confirmed by scanning electron microscopic images. The aluminum alloy-nano boron carbide composites show increased dislocation density, compared to the monolithic alloys, which was observed from the transmission electron microscopic images. The addition of nano-boron carbide in aluminum alloy matrix significantly improved its hardness and tensile strength, while the good ductility and impact resistance of the aluminum alloy was almost retained. The results of the dry sliding wear pin-on-disc tests showed improved wear resistance properties of aluminum alloy-nano boron carbide composites compared to the monolithic a...
TL;DR: In this paper, the authors review the research work carried out so far in the area of laser beam machining and its hybrid processes for different materials and shapes and highlight the research gaps and future research directions in the context of laser and laser-hybrid ablation.
Abstract: Laser beam machining (LBM) has proven its applications and advantages over almost all the range of engineering materials. It offers its competences from macro-machining to micro- and nano-machining of simple-to-complex shapes. The hybrid approaches in laser ablation have demonstrated much improved results in terms of material removal rate, surface integrity, geometrical tolerances, thermal damage, metallurgical alterations, and many more. The flipside of LBM is the existence of universal problems associated with its thermal ablation mechanism. In order to alleviate or reduce the inherent problems of LBM, a massive research has been done during the past decade in order to build a relatively new route of laser-hybrid processes. This paper reviews the research work carried out so far in the area of LBM and its hybrid processes for different materials and shapes. The article also highlights the research gaps and future research directions in the context of laser and laser-hybrid ablation.
TL;DR: In this paper, the authors investigated the method of depositing a ceramic coating on the surface of aluminum by means of electrical discharge coating (EDC) in electrical discharge machining (EDM).
Abstract: The present work investigates the method of depositing a ceramic coating on the surface of aluminum by means of electrical discharge coating (EDC) in electrical discharge machining (EDM). The present study makes use of powder metallurgy (P/M) green compacts made of titanium, boron carbide, and aluminum (Ti + B4C + Al) powder as the EDM tool for surface modification of aluminum workpieces. EDM process was carried out with different tool parameters like composition of the electrode material, compaction pressure of the green compacts, and different settings of the process variables like peak current and pulse duration setting. Responses observed were material deposition rate (MDR), tool wear rate (TWR), and average layer thickness (LT). Experiments were designed and carried out using Taguchi L18 orthogonal array. The most influential parameter for responses MDR, TWR, and LT was found to be peak current (Ip) with a percentage contribution of 60.72%, 59.52%, and 42.09%, respectively. In addition, various other...
TL;DR: In this article, the authors used hydroxyapatite (HA) powder suspension in deionized water during electrical discharge machining (EDM) of Ti6Al4V work material, and the machined surfaces were evaluated by scanning electron microscopy (SEM), energy dispersive spectroscopy, and optical microscopy.
Abstract: Hydroxyapatite (HA) powder suspension in deionized water was used as a dielectric liquid during electrical discharge machining (EDM) of Ti6Al4V work material. The machined surfaces were evaluated by scanning electron microscopy (SEM), energy dispersive spectroscopy, and optical microscopy. The powder particles in the dielectric liquid extensively migrated and formed an HA-rich layer on the work material surface under specific machining conditions. The result was attributed to the generation of secondary discharges due to altered discharge conditions. The particles divided the primary discharge channel into several secondary ones. When the main discharge channel subdivided into several sub-discharges with comparable energy densities, the particles in the discharge region got stuck among them. Then, they moved toward the melted cavities and penetrated the surface at the end of the discharge duration. The results suggest the process as a practical alternative for producing biocompatible interfaces or coating...
TL;DR: In this article, composite electrode (Cu-Mn) manufactured through powder metallurgy has been used to machine hot die steel (H11) by electrical discharge machining (EDM) process with the aim of inducing manganese and carbon into the machined surface.
Abstract: In the present research, composite electrode (Cu–Mn) manufactured through powder metallurgy has been used to machine hot die steel (H11) by electrical discharge machining (EDM) process with the aim of inducing manganese and carbon into the machined surface. Such alloying is expected to improve the microhardness and other surface characteristics. Best level of process parameters for better surface finish and high microhardness are found using Taguchi method. Six processing parameters are considered and their significance is investigated by analysis of variance. Techniques like energy dispersive spectroscopy, scanning electron microscopy, and X-ray diffraction are used to ascertain the surface characteristics. Surface machined at optimum process conditions for microhardness shows 93.7% improvement due to formation of cementite, ferrite and manganese carbide phases. Surface roughness having Ra value of 3.11 µm has been achieved.
TL;DR: In this article, an acetone-vapor polishing system was developed to smooth acrylonitrile butadiene styrene (ABS) parts fabricated by fused deposition modeling.
Abstract: Additive manufacturing (AM) is the process of fabricating 3D physical models by layered manufacturing without the need of molds or dies. The surface finish of AM physical models is not satisfactory for most general engineering purposes. The aim of this study is to develop an acetone-vapor polishing system to smooth acrylonitrile butadiene styrene (ABS) parts fabricated by fused deposition modeling (FDM). Acetone vapor dissolved the outer surface of ABS parts, and the surface roughness of ABS parts with complex geometries can be significantly reduced. The advantages of this system include the flexibility to maintain dimensional accuracy, high polishing efficiency, low equipment costs, and no waste chemicals compared with conventional approaches.
TL;DR: In this article, the effects of cryogenic liquid nitrogen (LN2) coolant during drilling of Ti-6Al-4V alloy material with three different levels of cutting speed (Vc) and feed rate (f) at a constant depth were investigated.
Abstract: This article is focused on experimental study of the effects of cryogenic liquid nitrogen (LN2) coolant during drilling of Ti–6Al–4V alloy material with three different levels of cutting speed (Vc) and feed rate (f) at a constant depth. Cutting temperature (T), thrust force (Fz), torque (Mz), surface roughness (Ra), and hole quality are the output responses investigated by using cryogenic LN2 coolant compared with a wet coolant. Tool wear and chip morphology were examined with the changes in cryogenic LN2 coolant. It is found that cryogenic LN2 coolant results in lowering cutting zone temperature which helps more removal of heat from the cutting zone. Lower thrust forces and surface roughness were observed due to less friction and better chip breaking in cryogenic LN2 condition. Also better chipping results in improvement in hole quality, viz., circularity and cylindricity in cryogenic LN2 condition. Less serration and uniform segmentation results in better chip morphology and no damage to the cutting ins...
TL;DR: In this paper, the authors examined how the material removal rate and tool wear rate vary with the variation in the tool rotation speed and their effects on the surface integrity of the workpiece.
Abstract: Electric discharge machining (EDM) is an acclaimed non-conventional machining process that is used for machining of hard or geometrically complex and electrically conductive materials which are extremely difficult to machine by conventional methods. One of the foremost demerits of this process is its very low material removal rate (MRR). For this, researchers have proposed some modifications like; providing rotational motion to the tool or workpiece, mixing of conducting fine powders (such as SiC, Cr, Al, graphite etc.) in the dielectric, providing vibrations to either the tool or the workpiece etc.The present research examines how the MRR and tool wear rates (TWR) vary with the variation in the tool rotation speed and their effects on the surface integrity of the workpiece. The results obtained clearly indicate that the tool rotation significantly improves the average MRR up to 49%. Moreover, the average surface finish also gets improved by around 9–10% while using the rotational tool EDM. Due to the too...
TL;DR: In this paper, the authors evaluate the performance of the different drill parameters in carbon fiber composites, including fiber pullout, delamination, surface finish, etc., among others.
Abstract: In recent years the use of carbon fiber composites in aerospace industries has been on the rise due to their unique properties like high specific strength, high stiffness, and fatigue characteristics. The machining behavior of these materials differs from machining homogenous metals because the drill bit encounters fiber and matrix alternatively which have widely different properties. Among the various machining operations, drilling is very common to facilitate assembly using fasteners to others parts in the structure. Rapid wear of the tool due to the abrasive carbon fibers is an important reason for damage occurrence. This results in frequent drill changes affecting the production cycle and increasing the final cost. Drill geometry is an important factor which decides the quality of the drilled hole. Hole quality is decided by a number of parameters like fiber pullout, delamination, surface finish, etc., among others. It is therefore necessary to evaluate the performance of the different drills availabl...
TL;DR: In this paper, material flow of the processed material with reinforcement particles demonstrated that the distribution of particles was influenced by the stirring action of the probe as well as the extrusion of the plasticized material due to the movement of the tool.
Abstract: Friction stir processing (FSP) is an important technique for preparing surface composites. Fabricating defect-free surface composites with uniform particle distribution by FSP is a challenging task. In this study, silicon carbide particles reinforced AA5083 alloy surface composites was fabricated using different FSP strategies including variation in process parameters, dual-tool processing and tool offset overlapping. Material flow of the processed material with reinforcement particles demonstrated that the distribution of particles was influenced by the stirring action of the probe as well as the extrusion of the plasticized material due to the movement of the tool. Process parameters, particularly rotational speed, showed a dominant influence on the distribution of silicon carbide particles.
TL;DR: In this article, different friction stir welds were produced in 3mm thick plates of AA6082-T6 and AA5083-H111 aluminum alloys using SiC as reinforcing material.
Abstract: Dissimilar friction stir welds were produced in 3 mm thick plates of AA6082-T6 and AA5083-H111 aluminum alloys using SiC as reinforcing material. The optimum weld presents a good distribution of nanoparticles in the weld nugget and mechanical mixing of the two alloys as well as further grain refinement compared to the one without nanoparticles. Higher hardness in the weld nugget is also evidenced, followed by enhanced ultimate tensile strength and elongation values. All specimens, after the tensile test, were lead to fracture at the heat affected zone of AA6082-T6 and specifically at the region of the lowest hardness.
TL;DR: In this article, the high-range parametric effects of drilling control factors on delamination damage and surface quality were investigated for hybrid carbon/glass fiber reinforced polymer (HFRP) composites in both research literature and industrial applications.
Abstract: Previous attempts at drilling of fibrous composites have been challenging due to the limited mechanical properties and presence of severe delamination damage at the top and bottom surfaces of the drilled hole. With the recent introduction of hybrid carbon/glass fiber reinforced polymer (HFRP) composites in both research literature and industrial applications, the need for evaluating their drillability is inevitable prior to their final usage. This is mainly because of the unique properties of HFRP composites as compared to the single-type FRP composites. Therefore, this paper aims to present a research initiative that will elucidate the high-range parametric effects of drilling control factors on delamination damage and surface quality. Taguchi methodology and statistical analysis of variance were applied to determine the performance of the drilling process. Experimental results revealed that delamination damage and surface quality values were strongly influenced by the feed and special tool geometries ra...