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IRJET- Synthesis and Comparative Machining Characterization of A356 - Graphite, A356 – Sic and A356 – Casio3 Composites
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IRJET- Synthesis and Comparative Machining Characterization of A356 - Graphite, A356 – Sic and A356 – Casio3 Composites
1.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 08 | Aug 2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1230 Synthesis and Comparative Machining Characterization of A356 - Graphite, A356 – SiC and A356 – CaSiO3 Composites Rajesh Kambala1, P. Suresh Babu2 1Student, Dept. of Mechanical Engineering, Narasaraopeta Engineering College, Andhra Pradesh, India 2Associate professor, dept. of Mechanical Engineering, Narasaraopeta Engineering College, Andhra Pradesh, India ---------------------------------------------------------------------***--------------------------------------------------------------------- Abstract - Metal matrix composites play an important role in automotive engineering, railway or subway cars, aerospace industry and military. At present investigation, the specimens of aluminum [A356] reinforced separately with 5% graphite powder,5% SiC powder and 5% calcium silicate powder were prepared using stir casting machine. These three different types of specimens were tested in on lathe for machinability studies in which cutting forces and machining capabilitieslike metal removal rate, surface roughness and also power consumption were studied at variouscuttingspeedsand depth of cuts. The cutting forces have shown increasing trend up to a speed of 50 m/min due to work hardening of composite and then decreased at high speeds due to softening of material. Metal removal rate and power consumption has shown increasing trend with respect to cutting speed as wellasdepth of cut. Machining times were calculated using CATIA V5R20 software and they were compared with practical values. A356- Graphite composite have shown better machining characteristics compared to other two composites Key Words: (Size 10 & Bold) Key word1, Key word2, Key word3, etc (Minimum 5 to 8 key words)… 1. INTRODUCTION 1.1 Metal Matrix Composites Now a days metal matrix composites (MMCs) are replacing conventional materials in many applications because of their superior properties such as high strengthto weight ratio, hardness, stiffness and wear and corrosion resistances over conventional materials. Silicon carbide particle (SiC) reinforced aluminium-based MMCsareamong the most commonMMCand commerciallyavailableones due to their economical production.In addition,thedevelopment of stir casting route for synthesis has brought down their cost to an acceptable level compared to those processed by powder metallurgy and spray casting process Particulate metal matrix composites have produced economically by conventional casting techniques. However, the stiffness, hardness and strength to weight ratio of cast MMCs are increased, but a substantial decrease in ductility has obtained. Composites are material consisting two or more natural or artificial materials to maximize their useful properties and minimize their weaknesses. Composites are typically used in place of metals because they are equally strong but much lighter. It consists of two or more distinct phases (matrix phase and reinforcing phase/phases) where individual phase retains its properties (physical,mechanical and chemical).Propertiessuchashighstiffness,highstrength to weightratio, low density, high temperature stability, high electrical and thermal conductivity, adjustable coefficient of thermal expansion, corrosion resistance, improved wear resistance etc. make composites attractive materials. The composite materials are classified into three categories. They are Polymer Matrix Composites (PMC), Metal Matrix Composites (MMC) and Ceramic Matrix Composites (CMC) based on matrix phase .At present work our experimental specimens are MMC’s and here matrix material is A356 and graphite, SiC, CaSiO3 are the reinforcement powders. 1.2 Machinability Machinability is a consideration in the materials selection process for different machine parts. The ease with which a metal can be machined is one of theprinciplefactors affecting a product's utility, quality and cost. The usefulness of a means to predict machinability is obvious. Unfortunately, machinability is so complex a subject that it cannot be unambiguously defined. Depending on the application, machinability may be seen in terms of tool wear rate, total power consumption, attainable surface finish or several other benchmarks.Machinability -thereforedepends a great deal on the viewpoint of the observer; in fact, the criteria for one application frequently conflict withthosefor another. At our present experiment the machining capabilities of three different metal matrix composites were tested at various cutting speeds and depth of cuts. 2. MATERIAL AND EXPERIMENTAL METHOD The specimens used in these experimentsaremetal matrix composites which are fabricated by reinforcing5% of graphite or SiC or CaSiO3 powder of 40-50µ size into aluminum [A356] using stir casting technique. 2.1 Matrix Material Aluminiun[A356] is used as matrix material in this experiment in which reinforcing powder is to be added during its molten state. A356 is a grade ofaluniniumandthis alloy consists 92.05% of Al, 7% of Cu , 0.35% of Mg ,0.1% of Zn and 0.1% of Mn. The following factors should be considered while choosing a matrix material.
2.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 08 | Aug 2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1231 Formability Weldability Machinability Corrosion resistance Heat treating The reasons for choosing A356 as matrix material are; alloys have very good casting and machining characteristics. Typically they are used in the heat-treated conditions. Corrosion resistance is excellent and it has very good weldability characteristics. Mechanical properties are rated excellent particularly if given a solution and aging treatment. The anodized appearance is gray in color. Typically thisalloy is used in castings for aircraft parts, pump housings, impellers, high velocity blowers and structural castings where high strength is required. It can also be used as a substitute for aluminum alloy 6061.The fact that 356 and A356 have good castability makes it a logical choice for intricate and complex castings where lightweight, pressure tightness and excellent mechanical properties are needed. 2.2 Reinforcement Material At this present work three different types of reinforcement powders were used which were discussed below 2.2.1 Graphite powder The first type of specimen is fabricated by reinforcing5% of graphite powder of particle size 40-50µ. The key property of commercial graphite is given below. Table – 1: Properties of graphite Bulk density 1.3-1.95 [g/cm3] Porosity 0.7-5.3 % Young’s modules 8-15 [GPa] Compressive strength 20-200[MPa] Flexural strength 6.9-100 [MPa] Coefficient of thermal expansion 1.2-8.2 [X10-6 0c] Thermal conductivity 25-470 [W/m K] Specific heat capacity 710-830 /Kg K] 2.2.2 Silicon Carbide [Sic] Powder 5% of silicon carbide particles of size 40-50µ were added into matrix material in second type of specimens. The characteristics of silicon carbide were given below. Low density High strength Good high temperature strength (Reaction bonded) Oxidation resistance (Reaction bonded Excellent thermal shockresistance High hardness and wearresistance Excellent chemical resistance Low thermal expansion and high thermal conductivity 2.23Calcium Silicate[CaSiO3] Powder In third type of specimen reinforcement material is 5%of calcium silicate powder of particle size 40-50µ.Itcanexhibit high condutvity, high stability, high purity, good wear resistance, low coefficient of thermal expansion and resistant to oxidation at high temperature. 2.3 Stir Casting Method The required three types of specimens were synthesized using a bottom pouring type stir casting furnace which contains the following components. A graphite stirrer is used to mix the matrix phase in molten state and preheated reinforcement powders homogenously bymechanicalstirring.Itwillhavebothrotary and reciprocating motions at a time. There is a separate unit called stirrer height controller by means of which motion of stirrer can be controlled. Melting furnace will heat the crucible in which solid matrix material is converted into molten metal. The reinforcement powder will be placed in another preheated furnace from which powder is released gradually into molten metal during the process of stirring. There a measuring and control unit which displays the temperature of furnace, melt, mould and reinforcement powder and also stirring speed. By using this unit the above parameters can be varied.Thefollowingprocedureshouldbe fallowed to synthesize the required specimens using stir casting machine. Set the temperature of furnace, melt, die and reinforcement powder according to the experimental conditions given below. Cut the aluminium ingots of 356 gradesmall pieces enough to place into the crucible. Heatthe matrix material to attain molten state up to 7900C. Place the
3.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 08 | Aug 2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1232 reinforcement powderinthecorrespondingfurnaceandheat it up to 2000C to 3000C based on type of powder. Keep the stirrer in ON position after the temperature of melt reached to 7900C which enables the stirrer to mix the molten metal with reinforcing powder homogeneously which is released gradually into the crucible. Stirrer can also be moved up and down by operating correspondingswitches.Afterthatswitch on the pour button on control unit which enablesthepouring of molten compositeinto the dieormouldandthenallowitto solidify after that remove the solid shaft [required specimen or work piece] from the die Fig - 1: Stir casting machine . Table – 2: Casting conditions Furnace Temperature 8500C Melt Temperature 7900C Powder Temperature 2000C for graphite 3000C for SiC 4000C for CaSiO3 Mould Temperature 2500C Pouring Temperature 7900C Stirring Speed 400 rpm Stirring Time 5 min Fig – 2: Experimental Specimens A356+ [5% wt] Graphite composite A356+[5% wt] SiC composite A356+[5% wt]CaSiO3 composite 2.4 Machinability Test The turning experiments were carried out for the three by using HSS tool bits inaautomaticlathemachine.The machining trials were performed with three cutting speeds (N) 202, 303, and 455 r.p.m with a constant feed (f) of 0.4 mm/rev and a depth of cut of 0.5 mm under dry environment. Cutting forces were measured on lathe tool dynamometerfacilityatNECcollege.Atthesametimesurface roughness values were also measured. The above machining trails were repeated with three depths of cut [Dc] 0.5, 0.75,1 mm at a constant speed of 303 r.p.m and constant feed of 0.4 mm/min. Fig - 4: Experimental set up The above procedure is repeated for three different specimens 2.4.1 Input Parameters We have given various cutting speeds, depth of cuts and feed as input parameters in order calculate various machining characteristics. Cutting speed [rpm] Depth of cut [mm] Feed [mm/rev] 2.4.2 Responses Measured During the machining, the values of cutting forces developed are taken from lathe tool dynamometer and by using these values metal removal rate and power were calculated. Surface roughness was also checked. Axial force [Fx] in N Cutting force or Tangential force [Fy] in N Radial force [Fz] in N
4.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 08 | Aug 2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1233 Power [P] in W Metal removal rate [MRR] in mm3/min Surface roughness in µm Fig – 3: lathe tool dynamometer 2.5 Determination of Machining Time Using CATIA The following procedure should be followed this experiment was done using CATIAV5R20.Opentwoseparate components one is for design part and other one is for stock element. Design the required shaft and stock part according to the dimensions of real specimens. Apply material tooth of them Unhide the sketch of the both parts which must visible during part selection. GO to machining and select lathe machining. Click on the partoperationandselecttypeoflathe machine and give maximum speed. The icons related to several lathe operations will be appeared on the screen and click on rough turning and give values of depth of cut, speed and feed as input. Select the tool geometry, axes. Give the path for both design part and stock and run the programme,we will get machining time as output at a given feed rate. Repeat the above procedure for various cutting speeds and depth of cuts according to the practical experiment Fig -3: Design part with stock Fig – 4: applying material Fig – 6: output machining time Table – 3: machining time in sec [practical vs. CATIA] 2.6 Results and Discussions After loading the component on the lathe machine plane turning operation has performed and specimen is divided into six divisions to perform six operations by varying speed and depth of cut parameters. Feed is kept constant in every time. 2.6.1 Effect Of Speed On Cutting Forces this situation turning operation is carried out at different cutting speeds like 202, 303 and 455 rpms at the same time feed and depth of cut are kept constant. Cutting forces values are taken from lathe tool dynamometer Table – 3: Effect of Speed on Cutting Forces Cutting speed (rpm) Fx (N) Fy (N) Fz (N) For A356+[5% wt] Graphite composite 202 39.24 147.15 176.58 303 78.48 235.44 225.63 455 68.48 196.2 186.01 For A356+[5% wt] SiC composite 202 117 304 255 303 137 343 294 455 78 215 186 For A356+[5% wt]CaSiO3 composite Speed [rpm] A356+Graphite A356+SiC A356+CaSiO3 p C P C p c 202 151.12 148.51 145 148.51 153 148.51 303 95.34 99.00 95 99.00 98 99.00 455 62.12 65.93 65 65.93 64 65.93
5.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 08 | Aug 2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1234 202 58.86 294.3 245.25 303 176.58 382.59 274 455 117.72 313.92 255 2.6.2 Effect of depth of cut on cutting forces: Under this situation turning operationiscarriedout by giving different depth of cuts like 0.5, 0.75 and 1 mm. while cutting speed and feed are constant. Again cutting forces values are taken from lathe tool dynamometer Table – 4: Effect of depth of cut on Cutting Forces Depth of Cut (mm) Fx (N) Fy (N) Fz (N) For A356+ [5% wt] Graphite composite 0.5 88.29 196.01 184 0.75 92 206.2 215.82 1.0 147.15 294.3 274.68 For A356+ [5% wt] SiC composite 0.5 156 196.01 313 0.75 176 226.2 333 1.0 186 294.3 372 For A356+ [5% wt] CaSiO3 composite 0.5 58.86 196.2 225.63 0.75 137.34 304.11 284.49 1.0 147.15 333.54 313.92 2.6.3 Machining Results By using the values collected from lathe tool dynamometer we calculated power and material removal rate and by using surf test instrument we checked surface roughness of machining specimen. Table – 5: Effect of speed on machining capabilities Cutting speed (rpm) Power (W) MRR (mm3/min) Surface roughness (µm) For A356+[5% wt] Graphite composite 202 71.5 8.42 25.5 303 171.6 14.52 18 455 215 20.5 14.55 For A356+ [5% wt] SiC composite 202 174.33 8.75 29.09 303 223.83 13.92 19.01 455 246 18.19 17.02 For A356+ [5% wt]CaSiO3 composite 202 147.83 9.138 28.16 303 288.16 13.70 25.54 455 354.6 20.08 15.27 Table – 5: Effect of depth of cut on machining capabilities Depth of cut (mm) Power (W) MRR (mm3/min) Surface roughness (µm) For A356+[5% wt] Graphite composite 0.5 101.16 8.42 11.22 0.75 143 14.52 13.16 1.0 322.5 18.276 18.06 For A356+[5% wt] SiC composite 0.5 204.16 8.75 13.67 0.75 268.92 13.92 14.08 1.0 403.83 16.15 25.40 For A356+[5% wt] CaSiO3 composite 0.5 54 6.092 10.17 0.75 229 13.707 14.77 1.0 377 16.09 21.16 Graph – 1: Axial force Vs. Speed Graph – 2: Tangential force Vs. Speed
6.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 08 | Aug 2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1235 Graph – 3: Radial force Vs. Speed The above three graphs show the comparision of cutting forces at diferent cutting speeds in which all the cutting forces increases up to a speed of 303 rpm and then decreased at higher speeds.The cutting forces developed in graphitecompositearelessthanthatofothertwocomposites Graph – 4: axial force Vs. Depth of cut Graph – 5: Tangential Force Vs. Depth Of Cut Graph – 6: Radial Force Vs. Depth Of Cut Theabovethreegraphsshowthecomparisoncutting forces at various depths of cuts. The induced cutting forces h ofas been completed, Out of three compositesSiCcomposites involves more cutting forces than the other two composites. Graph – 7: MRR vs. Speed Graph – 8: MRR Vs. Depth of cut Graph – 9: Power vs. Speed Graph – 10: Power vs. Depth of cut
7.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 08 | Aug 2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1236 Graph – 11: Surface roughness vs. Speed Graph – 12: Surface roughness vs. Depth of cut From the above graphs it is clear that MRR, power,increases non linearlywiththecuttingspeedwhereas surface roughness is decreased case of all the three composites.It is also noticed that power, MRR suface roughneshh were incresed with depth of cut. 3. CONCLUSIONS A356matrix composites have successfullyprepared by using stir casting technique. Cutting forces have shown increasing trend up to a speed of 50m/min due to work hardening of the composite, and then decreased at high speed due to softening of the material. MRR has shown increasing trend with respect to speed whereas surface roughness has shown decreasing trend Due to increase in depth of cut, the tool has to deal with higher volume of material which will ultimately result in an increase in the force as well as power consumption. MRR and surface roughness has shown increasing trend with respect to depth of cut for all the three composites. Machining time was calculated using CATIA and compared with practical values. It will take less machining time if use corresponding tool A356-graphite composite has shown best machinability characteristicswhen comparedother two to composites. REFERENCES [1] Anil K.C, M.G Vikas, shanmuka teja, K.V srinivasarao “effect of cutting parameters on surface finish and machinability graphite reinforced AI-8011 matrix composite. [2] Varun Nayyar and Jacek Kaminski.,(2012) “ An Experimental Investigation On Graphitic Cast Iron Grades;Flake,CompactedAndSpherodal GraphiteIronin Continuous Machining Operations “ [3] Adbullah Altin (2013) “ The Effect Of Cutting Speed On Cutting Forcesand Surface Finish When Milling Chromium210 Cr 12steel Hard Facing With Uncoated Cutting Tools” [4] Surappa, M.K. and Rohatgi, R.K., (1981)Journal of Material Science, Vol. 61,983-993 [5] Mechanics of composite materials by AUTAR K. KAW
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