Functional Composite Materials: Manufacturing Technology and Experimental Application

C. Samson Jerold Samuel, M. Suresh, S. Gnanasekaran, C. Samson Jerold Samuel, M. Suresh, S. Gnanasekaran

• Publisher: Bentham Science Publishers
• Year: 2001
• Print ISBN: 9789815039917
• eBook ISBN: 9789815039894
• Topic: Physical Sciences
• Subtopic: Physics
• Index: Physics

This book highlights the advancements in the manufacture and testing of functional composites, metal matrix composites and polymer matrix composites. Chapters provide information about machinability studies of metals and composites using a variety of analytical techniques. The 12 book chapters also highlight updates in manufacturing technologies like CNC turning processes, electrical discharge machining, end milling, abrasive jet machining, electro chemical machining, additive manufacturing, and resistance spot welding. Readers will learn how to solve applied problems in industrial processing and applications. The book is of significant interest to industrialists working on the basic and experimental parameters for fabricating functional composites and manufacturing technology. Because of the multidisciplinary nature of the presented topics, the information presented in the book is of value to a broad audience involved in research, including materials scientists, chemists, physicists, manufacturing and chemical engineers and processing specialists who are involved and interested in the frontiers of composite materials.

Optimization of Machining Process Parameters to Calculate Surface Finish, Metal Removal Rate, and Cutting Force on AA6061-T6 Alloy

Karthik Pandiyan G.^{1, *}, T. Prabaharan², Jafrey Daniel James D.³

¹ Department of Mechanical Engineering, Sri Vidya College of Engineering and Technology, Virudhunagar, Tamil Nadu, India

² Department of Mechanical Engineering, Mepco Schlenk Engineering College, Sivakasi, Tamil Nadu, India

³ Department of Mechanical Engineering, K.Ramakrishnan College of Engineering, Trichy, Tamil Nadu, India

Abstract

In this study, CNC turning process parameters are optimized while machining AA6061 – T6 alloy. The process variables, namely, cutting spindle speed or spindle velocity (Cs), rate of feed (Fr), rate of the depth of cut (Dc), and nose radius (Nr), were optimized with output responses such as surface roughness (Ra), feed power (Fx), thrust power (Fy), cutting power (Fz), and removal rate of material (MRR). The optimized results showed higher MRR, Fy, and Fz and lower Fx and Ra were obtained at a cutting spindle speed or spindle velocity (Cs) of 100 rev/min, rate of feed (Fr) of 0.2 mm/min, depth of cut (Dc) of 1.5 mm/min, and nose radius (Nr) of 0.8 mm. TOPSIS and ANOVA were used to assess the experimental results to determine the most favourable factors that were superior and suitable for selecting the optimal variable condition.

Keywords: AA6061-T6 alloy, ANOVA, CNC Turning, Cutting power, Depth of the cut, Feed power, Material removal rate, Multiresponse Optimization, Nose radius, Rate of feed, Spindle Speed, Surface roughness, Thrust power, TOPSIS.

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^* Corresponding author Karthik Pandiyan G.: Department of Mechanical Engineering, Sri Vidya College of Engineering and Technology, Virudhunagar, Tamil Nadu, India; E-mail: [email protected]

INTRODUCTION

Aluminium is ductile and has an FCC (Face Centred Cubic) structure. Al is a lighter metal with 2900 kg/m³ as density. It has higher electrical and thermal conductivity due to its lower density. Various wrought aluminium products include mechanical finishes, chemical finishes, and coatings.

Mechanical finishes include cold finished, buffed, and textured coatings, whereas chemical finishes include etched, bright dipped, and chemical conversion coatings. Anodizing, painting, plating, and chemical conversion coatings are included in the coating category. Due to low density to high strength ratio, toughness, and corrosion resistance, aluminium alloys are mainly used in automobiles and aerospace Industries. Zn, Si, Mg, Cu, are major alloying elements that are classified into cast-based alloys and wrought-based alloys with heat-treatable and non-heat-treatable properties.

Chemical composition of AA6061-T6 (T6- heat-treated, rapid cooling and aged) is Al - 97.25%; Cu - 0.32%; Mg - 1.08%; Mn - 0.52%; V - 0.01%; Fe - 0.17%;Sic - 0.63%; Ti - 0.02%, which is a work-hardened alloy with a low density to high strength ratio, increased hardness, improved toughness, capability of welding, and greater resistance to corrosion. The strain hardening method is highly effective in improving the strength of materials.

Due to tem...

Table of contents

• Welcome
• Table of Content
• Title
• BENTHAM SCIENCE PUBLISHERS LTD.
• FOREWORD
• PREFACE
• List of Contributors
• Optimization of Machining Process Parameters to Calculate Surface Finish, Metal Removal Rate, and Cutting Force on AA6061-T6 Alloy
• Machinability Analysis and Optimization by the Taguchi-gra-pca Approach of PMEDM Process Parameters of Monel K 500
• Analyzing the Influence of RSW Process Parameters on the Cross Tension Failure Load of Dissimilar functionally graded AISI 304/316L Stainless Steel Sheets
• A Review on Manufacturing of Aluminium Alloy Based Metal Matrix Composites through Stir Casting Route
• Experimental Analysis of Different Machining Parameters on Epoxy Granite Composite
• Analysis on Synthesized Carbon Aerogels Doped with Resorcinol Formaldehyde by XPS and Fesem Techniques
• Tribological Behaviour of Hybrid Natural Fiber Polymer Composites with Novel Fillers
• Application of Natural Fiber-reinforced Composites in Additive Manufacturing
• Investigation of Ionic Transport in Ionic Liquid BMIMBF4 Incorporated in ZnBDC-Metal-Organic Framework Based PVdF-HFP Composite Membranes
• Manufacturing Techniques and Applications of Multifunctional Metal Matrix Composites
• Machining Studies of Basalt Fiber Reinforced Aluminium Metal Matrix Composites Using Abrasive Jet Machining
• Multi-objective Optimization on Processing Parameters for Micro ECM of Inconel Alloy Using Taguchi Based Grey Relation Analysis