Influence of Machining Parameter on Tool Life While Machining Hybrid Metal Matrix Composites

A metal matrix composite constitutes a continuous metallic matrix and a discontinuous phase known as reinforcement. The hybrid metal matrix composites (Hmmcs) have been used to manufacture drive shafts, disc brake rotors, brake drums, connecting rods pistons, engine block cylinder liners for automotive and rail vehicle applications. The Hmmcs castings of diameter 120 mm and length 300 mm were prepared through sand mould technique following stir casting methodology. The cast components further subjected to evaluation of physical properties and machining tests using two grades of coated inserts and PCD inserts. The experiments were carried out following ISO 3685 standards. The coating thickness of the TiN coated and TiAlN coated inserts were measured using Kalo testing method; the results of the test show that the interface of the substrate and coating was free from the porosity, and the coating thickness of TiN coating was 4.84 microns and TiAlN coating was measured 4.6 microns. The results of the experiments show that performance of the PCD insert was better than coated inserts at 0.1 mm/rev feed; however at 0.2 mm/revolution feed PCD insert failed by micro chipping of cutting edge while machining Hmmcs. When TiAlN coated inserts were used to machine Hmmcs the coated inserts failed by gradual wear and BUE formation.

Fabrication, Characterization and Machining of Al6061 Reinforced with Red Mud Composite

The Metal Matrix Composites application has increased in many areas of science and technology, because of its additional physical, wear and mechanical properties. In comparison with all MMC’s, aluminum-based MMC’s are finding wide applications due to their better strength to weight ratio, better stiffness, and high thermal conductivity as well as very good wear and corrosion properties. The properties of a composite mainly depend on better distribution of reinforcement in the matrix, which is very difficult to achieve. Basically Redmud is a byproduct of alumina, and it is waste product obtained during Bayer’s process. This waste product must be recycled else it may be dangerous to the environment. Redmud can be used as reinforcement for aluminium composites in order to achieve better properties. The proposed research work includes preparation of Aluminum 6061-Red mud metal matrix composites using liquid metallurgy route following stir casting technique. An alloy Al6061 containing 0.60 percent silicon and Magnesium of 0.82 percent was used as the matrix material. Two different compositions of the Aluminum 6061-Red mud composites are prepared in addition to the base matrix and evaluated for mechanical properties also the force acting on the cutting tool at different spindle speeds during machining of the composite materials were analyzed.

Experimental Study on Polymer Nanocomposites Based Strain Sensors for Structural Health Monitoring

The aim is to develop a mechanically flexible polymer nanocomposite film-based strain sensors that could act towards sustainable structural health monitoring for civil structures. The developed polymer nanocomposite film combinations will be monitored for their structural, electrical and mechanical behaviors and the optimized formulations will be tried for strain sensing applications. The films were cast by using PVA as the base polymer and copper doped silver nitrate as the nanofiller along with the use of glycine as fuel which is a combination of silver and copper nitrate. After preparing the films, they were tested for conductivity under tensile loading using a digital multi meter connected to a UTM. The samples were subjected to XRD, FTIR and SEM for further analysis. The results of the experiments shown I-V characteristics of PVA-CuAgO composites from 5% to 25% CuAgO have been increased tremendously with the incorporation of filler material. For 100 V, the maximum current value obtained for plain PVA is only 7.7E-8 A, whereas CuAgO particles shown 0.0025 A at 5% reinforcements and further increased nearly to 0.025 A for 25% of CuAgO particles into the PVA matrix.