PSI - Issue 37

Jin Kim et al. / Procedia Structural Integrity 37 (2022) 282–291 Kim et al./ Structural Integrity Procedia 00 (2021) 000 – 000

285

4

The metal matrix composite (MMC) workpiece used for the experiments were two different types of SiCp/Al 2124 composite (matrix composition: Al:93.5%, Cu:4.3%, Mg:1.3%, Mn:0.3%, Si:0.2%) manufactured by Materion UK. Detailed specifications, including mechanical and thermal properties, are shown in Table 1.

Table 1 Workpiece specifications

Type

217XG

225XE

Material

SiCp/Al 2124

SiCp/Al 2124

Volume fraction (vol %) Particle size (µm) / shape Manufactured method Density, (kg/m 3 ) Yield Strength, (MPa) Elastic modulus, (Gpa) at 25ºC Thermal expansion coefficient Specific heat, , (J/g·K) Elongation to failure %

17

25

< 0.3 / angular

< 3 / angular

PM, HIP’ed, extruded

PM, HIP’ed, extruded

2960

2880

530

440 115

98 1.7 × 10 -5 0.848

1.61 × 10 -5 0.848

3

1.9

2.2. Experimental procedure and post-processing of results First, conventional turning (CT) and ultrasonically assisted turning (UAT) of 217XG was performed at four different cutting speeds, , and depth-of-cut, , with a 0.4 mm radius cemented carbide tool. The workpiece diameter and cutting length for each and was Ø 47 mm and 10 mm. Next, CT and UAT of two different SiCp/Al 2124 composites (Ø 90 mm) were implemented at fixed cutting conditions for the current setup. All experiments were implemented under dry (no-coolant use) conditions with constant cutting parameters, tool orientation, and vibration settings throughout. The experimental procedure used is summarised in Table 2.

Table 2 Experimental procedure

Depth-of-cut, , (mm)

Cutting speed, , (m/min) 10/20/30/60

Feed, , 0.1

Tool radius (mm)

Workpiece brand

Tool material

Vibration setup =20.33 kHz − (μm): Tangential/Ra dial/Feed = 28/7/9

No.

Method

(mm)

1

CT/UAT

217XG

0.1

0.4

Carbide

2

CT/UAT

217XG

30

0.1/0.12/0.14/0.16

0.1

0.4

Carbide

217XG/ 225XE 217XG/ 225XE

3

CT/UAT

25

0.15

0.14

0.8

Carbide

25

0.15

0.14

0.8

PCD

-

4

CT

The surface profile and roughness were then analysed using a non-contact surface analyser (Manufacturer: Bruker, Austria, Model: Alicona InfiniteFocus G5+) for each machined surface. 3. Finite element (FE) simulation analysis Numerical modelling of the CT and UAT processes (Exp. 3 & 4) was implemented using the general-purpose finite element software, ABAQUS. A 3D model was developed to represent the machining process accurately in contrast to popular 2D model equivalents by Kim et al. (2019). The cutting parameters and conditions for the simulation were identical to the experimental setup conditions.