This document discusses a bachelor project on composites conducted by three students and supervised by Prof. Dr. Helmi Abdel Maksoud Youssef. It examines the machinability of aluminum-silicon alloy composites reinforced with nickel microparticles and aluminum oxide nanoparticles. Experiments were conducted to evaluate how drilling parameters like speed, feed force, and drill diameter affect power consumption, depth, and specific cutting resistance. Results showed that nano- and micro-composites had better machinability than the base alloy due to their higher ductility and strength. Microhardness was also measured for the different specimens.

1. Alexandria University
Production Engineering
Discussion of
bachelor project
Supervisor:
Prof. Dr. Helmi Abdel Maksoud Youssef

2. Team members
 Mohamed Abdel kader sawah
 Mohamed Abdel Wahab Hassaan
 Mahmoud Hamed Mustafa Hussein

3. Composites
Composites
Matrix Reinforcements

4. Matrix
Matrices
Polymers
Thermosets Thermoplastics
Metals Ceramics Carbon

5. Reinforcements
Reinforcements
Fibers Filled
Particle filled microspheres
Whiskers Flakes Particulates
Directionally
solidified
eutectics

6. Applications
 Aircrafts,
 Military ships,
 Sports equipments,
 Construction (concrete),
 Bridges,
 Automotive,
 Moulds, etc.

7. Applications
Sandwich panels
Golf bats
Robot military planes
Pump impellers

8. Advantages
 High resistance to fatigue and corrosion.
 High resistance to impact damage.
 High strength or stiffness to weight ratio.
 Less inspections and structural repairs.
 Improved friction and wear properties.

9. Disadvantages
 High cost of raw materials and fabrication.
 Transverse properties may be weak.
 Analysis is difficult.
 Reuse and disposal may be difficult.
 Difficult to attach.

10. Machinability
 In general, machinability differs for each material.
 But it’s not a material constant.
 Machinability depends on machining conditions.
 It also depends on the physical and chemical
properties of work part.

11. Factors affecting machinability
 Forms of chip,
 Surface of machined part,
 Tool condition,
 And cutting forces.

12. Parameters of machinability
 Mechanical properties of work part,
 Cutting tool; material and geometry,
 Levels of process parameters,
 Machining environment; lubrication, etc.,
 Rigidity and stiffness of M/C,
 Type of machining operation.

13. Traditional machining
Milling
Turning
Grinding

14. Traditional machining
Drilling

15. Machining parameters
 Cutting speed,
 Cutting forces,
 Workpiece, and tool materials,
 Lubrication,
 Feed rate.

16. Samples preparation
 Al-Si alloy “piston alloy”(11.56% Si),
 Nickel micro particles,
 Al2O3 nano particles.

17. Samples preparation
 Melting of matrix alloy (at 700 °C).
 Preheating of reinforcing particles (at 400°C for 30
min).
 Mechanical stirring and squeeze casting.

18. Samples

19. Microstructure
Base alloy MMC I
MMC II MMC III

20. Microstructure
MMNC IV MMNC V

21. Rapid drilling test
 Different cutting speeds,
 High thrust forces,
 Short machining time,
 Sharp tools.
16-speeds bench drill

22. Equipment
 Powermeter (η = 95%),
 Avometer (η = 99%),
 Thrust weights (30, 40, and 50 Kg),
 High speed steel AISA M42 (6mm, and 8mm),
 103-lit carbide drill bit(6mm),
 16-speeds bench drill (E-type).

23. Experiments
Rapid drilling
test
Group 1 Group 2 Group 3

24. Group 1
 Drill diameter: 8mm
 Speed: 770 RPM (19.35 m/min)
 Feed forces: 300, 400, and 500 N
 Machining time: 10 sec
 Materials:
Base alloy
Al-Si base alloy + 5%wt. Ni
Al-Si base alloy + 10%wt. Ni
Al-Si base alloy + 15%wt. Ni
Al-Si base alloy + 5%wt. Ni + 2%wt 𝐴𝑙2𝑂3
Al-Si base alloy + 5%wt. Ni + 3%wt 𝐴𝑙2𝑂3

25. Group 1
Sample
No#
RPM
Feed
Force
(N)
𝑷𝟏 (W) 𝑷𝟐 (W) P2-P1 (W)
Ks
(N/𝒎𝒎𝟐)
Ksmax-Ksmin MR
Depth
(mm)
MR
Feed rate
(mm/rev)
8
770
300
320.78
339.19 18.41 406.05
100.38 100
9.020
100
0.070286
400 342.28 21.50 332.24 12.875 0.100325
500 349.13 28.35 305.67 17.150 0.133636
1
300 339.40 18.62 388.95
67.84 148
9.525
113
0.074221
400 349.28 28.50 361.78 15.675 0.122143
500 352.13 31.35 321.11 19.425 0.151364
5
300 341.65 20.87 385.38
71.06 141
10.775
112
0.083961
400 348.67 27.89 359.16 15.450 0.12039
500 352.02 31.24 314.32 19.275 0.154091
7
300 345.45 24.67 543.8758
96.32 104
9.025
109
0.070325
400 350.15 29.37 512.6012 11.400 0.088831
500 362.90 42.12 447.5552 18.725 0.145909
3
300 352.50 31.72 576.36
55.45 181
10.950
118
0.085325
400 364.52 43.74 531.36 18.625 0.14513
500 373.6 52.82 520.91 20.175 0.157208
4
300 351.5 30.72 597.78
61.48 163
10.225
112
0.079675
400 367.61 46.83 538.59 17.300 0.134805
500 372.6 51.82 536.30 19.225 0.149805

26. Group 1
Effect of thrust on consumed power Effect of thrust on penetration depth

27. Group 1
Effect of thrust on feed rate Effect of feed rate on specific cutting resistance

28. Group 2
 Drill diameter: 8mm
 Speeds: 770, 640, and 480 RPM(19.35, 16.077, 12.058 and
m/min)
 Feed force: 400 N
 Machining time: 10 sec
 Materials:
Base alloy
Al-Si base alloy + 5%wt. Ni
Al-Si base alloy + 10%wt. Ni
Al-Si base alloy + 15%wt. Ni
Al-Si base alloy + 5%wt. Ni + 2%wt 𝐴𝑙2𝑂3
Al-Si base alloy + 5%wt. Ni + 3%wt 𝐴𝑙2𝑂3

29. Group 2
Sample
No#
RPM
Feed
Force
(N)
𝑷𝟏 (W) 𝑷𝟐 (W) P2-P1 (W)
Ks
(N/𝒎𝒎𝟐)
Ksmax-Ksmin MR
Depth
(mm)
MR
Feed rate
(mm/rev)
8
770
400 320.78
345.45 24.67 335.84
64.07 100
14.60
100
0.113875
640 339.35 18.57 345.22 10.70 0.100325
480 334.48 13.70 399.91 6.85 0.085191
1
770 352.5 31.72 402.58
47.39 135
15.65
107
0.122143
640 338.65 17.87 413.39 8.60 0.080625
480 330.50 9.72 449.97 4.30 0.053719
5
770 357.20 36.42 468.97
57.91 111
15.45
105
0.12039
640 346.35 25.57 502.01 10.15 0.095
480 339.65 18.87 526.88 7.5 0.089063
7
770 350.15 29.37 479.83
59.46 108
14.65
101
0.11416
640 344.03 23.25 488.16 9.45 0.088831
480 331.99 11.21 539.29 4.15 0.05175
3
770 363.9 43.12 460.64
40.58 158
18.65
127
0.14513
640 346.00 25.22 485.79 10.35 0.096875
480 339.26 18.48 501.22 7.35 0.091688
4
770 361.3 40.52 466.02
43.68 147
17.30
118
0.134805
640 344.3 23.52 482.29 9.70 0.091
480 338.90 18.12 509.70 7.05 0.088406

30. Group 2
Effect of rotational speed on power Effect of rotational speed on depth

31. Group 2
Effect of feed rate on consumed power Effect of feed rate on specific cutting resistance

32. Group 3 I
 Drill diameter: 6mm,
 Speed: 640 RPM (12.057 m/min),
 Feed force: 300, 400, and 500 N,
 Machining time: 10 sec,
 Materials:
Base alloy
Al-Si base alloy + 5%wt. Ni
Al-Si base alloy + 10%wt. Ni
Al-Si base alloy + 15%wt. Ni
Al-Si base alloy + 5%wt. Ni + 2%wt 𝐴𝑙2𝑂3
Al-Si base alloy + 5%wt. Ni + 3%wt 𝐴𝑙2𝑂3

33. Group 3 I
Sample
No#
RPM
Feed
Force
(N)
𝑷𝟏 (W) 𝑷𝟐 (W) P2-P1 (W)
Ks
(N/𝒎𝒎𝟐)
Ksmax-Ksmin MR
Depth
(mm)
MR Feed rate (mm/rev)
8
640
300
320.78
330.65 9.57 387.71
92.3818 100
8.73
100
0.081844
400 331.35 10.57 330.1098 11.33 0.106219
500 333.70 12.92 295.3282 15.48 0.145125
1
300 323.95 3.87 135.11
53.71 172
11.23
126
0.105281
400 324.80 4.02 85.286 16.68 0.156375
500 325.25 4.47 81.41 19.43 0.182156
5
300 326.76 5.98 208.79
56.74 163
10.93
123
0.102469
400 327.74 6.96 156.29 15.75 0.147656
500 329.00 8.22 152.04434 19.13 0.179344
7
300 329.57 9.62 335.87
88.49 104
10.13
119
0.094969
400 331.83 11.05 255.76819 15.28 0.14325
500 333.70 12.92 247.3854 18.48 0.17325
3
300 329.02 8.24
297.3779
4
38.60 239
9.80
135
0.091875
400 331.35 10.57 262.4664 14.25 0.133594
500 336.05 15.27 258.7748 20.88 0.19575
4
300 334.00 13.22 409.0664
44.64 207
11.43
125
0.107156
400 337.70 16.92
372.8483
4
16.05 0.150469
500 340.75 19.97 364.4296 19.39 0.181781

34. Group 3 I
Effect of thrust on consumed power Effect of thrust on penetration depth

35. Group 3 I
Effect of thrust on feed rate Effect of feed rate on specific cutting resistance

36. Group 3 II
 Drill diameter: 6mm
 Speed: 640, 1240, 1640, 2350 RPM (12.058, 23.36, 30.9,
and 44.27 m/min)
 Feed force: 400 N
 Machining time: 10 sec
 Materials:
Base alloy
Al-Si base alloy + 15%wt. Ni
Al-Si base alloy + 5%wt. Ni + 3%wt 𝐴𝑙2𝑂3

37. Group 3 II
Sample
No#
RPM
Feed
Force
(N)
𝑷𝟏 (W) 𝑷𝟐 (W) P2-P1 (W)
Ks
(N/𝒎𝒎𝟐)
Ksmax-Ksmin MR %
Depth
(mm)
MR % Feed rate (mm/rev)
8
640
400 320.78
326.65 5.87 349.687
1689.953
100
5.94
100
0.055688
1240 367.55 46.77 2039.64 8.11 0.039242
1640 389.6 68.82 1977.24 12.31 0.045037
2350 431.725 110.945 1878.36 20.89 0.053336
7
640 329 8.22 443.4001
1167.92
145
6.56
103
0.0615
1240 363.15 42.37 1611.32 9.3 0.045
1640 377.43 56.645 1467.70 13.65 0.049939
2350 409.5 88.72 1457.43 21.53 0.05497
4
640 331.35 10.57 522.3839
1129.84
150
7.16
107
0.067125
1240 368.15 47.37 1652.22 10.14 0.049065
1640 389.25 68.47 1617.67 14.97 0.054768
2350 421.4 100.62 1596.54 22.29 0.056911

38. Group 3 II
Effect of rotational speed on power Effect of rotational speed on penetration depth

39. Group 3 II
Effect of feed rate on specific cutting resistance

40. Conclusion
 The machinability of composites is higher than the
base alloy.
Nano
composites
Micro
composites
Base alloy
Machinability decreasing

41. Tensile strength
 As the ductility of composites are higher than the base
alloy, it indicates that the machinability of composites
are going to be better than the base alloy.
Material UTS(MPa)
Engineering strain 𝜺
(%)
Base material 296.0 4.8
MMC I 369.7 5.0
MMC II 362.9 5.7
MMC III 310.5 6.0
MMNC IV 390.0 5.9
MMNC V 350 4.4

42. Microhardness
 Microhardness of the different specimens was measured
using microhardness tester. The applied load was 100 g.
Specimen 8 1 5 7 3 4
Vickers(HN) 152.33 119.67 145 197 121.33 150