Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 30309
Tool Wear of Metal Matrix Composite 10wt% AlN Reinforcement Using TiB2 Cutting Tool

Authors: R. Othman, M. S. Said, J. A. Ghani, Che Hassan C. H., N. N. Wan, M. A. Selamat


Metal matrix composites (MMCs) attract considerable attention as a result from its ability in providing a high strength, high modulus, high toughness, high impact properties, improving wear resistance and providing good corrosion resistance compared to unreinforced alloy. Aluminium Silicon (Al/Si) alloy MMC has been widely used in various industrial sectors such as in transportation, domestic equipment, aerospace, military, construction, etc. Aluminium silicon alloy is an MMC that had been reinforced with aluminium nitrate (AlN) particle and become a new generation material use in automotive and aerospace sector. The AlN is one of the advance material that have a bright prospect in future since it has features such as lightweight, high strength, high hardness and stiffness quality. However, the high degree of ceramic particle reinforcement and the irregular nature of the particles along the matrix material that contribute to its low density is the main problem which leads to difficulties in machining process. This paper examined the tool wear when milling AlSi/AlN Metal Matrix Composite using a TiB2 (Titanium diboride) coated carbide cutting tool. The volume of the AlN reinforced particle was 10% and milling process was carried out under dry cutting condition. The TiB2 coated carbide insert parameters used were at the cutting speed of (230, 300 and 370m/min, feed rate of 0.8, Depth of Cut (DoC) at 0.4m). The Sometech SV-35 video microscope system used to quantify of the tool wear. The result shown that tool life span increasing with the cutting speeds at (370m/min, feed rate of 0.8mm/tooth and DoC at 0.4mm) which constituted an optimum condition for longer tool life lasted until 123.2 mins. Meanwhile, at medium cutting speed which at 300m/m, feed rate of 0.8mm/tooth and depth of cut at 0.4mm we found that tool life span lasted until 119.86 mins while at low cutting speed it lasted in 119.66 mins. High cutting speed will give the best parameter in cutting AlSi/AlN MMCs material. The result will help manufacturers in machining process of AlSi/AlN MMCs materials.

Keywords: Tool Wear, AlSi/AlN Metal Matrix Composite milling process, TiB2 coated cemented carbide tool

Digital Object Identifier (DOI):

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2754


[1] MetinKoK, “Tool life modeling for evaluation the effects of cutting speed and reinforcements on the machining of particle reinforced metal matrix composites,” Int. Journal of Minerals, vol. 17, no. 3, pp. 353, June 2010.
[3] S. S. Joshi, N. Ramakrishnan, D. Sarathy, P. Ramakrishnan, “Development of the technology for discontinuously reinforced aluminium composites,” in Proc. World Conference on Integrated design and Process Technology, Austin, 1995, pp. 297.
[4] M.J Kocazac, S.C. Khatri, J.E Allision and M.G Bader, “MMCs, for ground vehicle, aerospace and industrial application,” Fundamentals of Metal Matrix Composite. Guildford, UK 1993, pp. 297
[5] N. P. Hung, F.Y.CBoey, K. A. Khor, et al., “Machinibility of cast and powder-formed aluminium alloys reinforce with SiC particles,” J. Material Process. Technol., vol. 48,pp. 291-297 January 1995.
[6] GusriAkhyar Ibrahim, “PelarikanAloi Titanium Ti-6A1-4V ELI MenggunakanPerkakasKarbidaDalamKeadaanKering,” PhD Thesis, UniversitiKebangsaan Malaysia, 2010, unpublished.
[7] Y. Sahin, G. Sur, “The effect of Al2O3TiN and Ti (C,N) based CVD coating tool on wear in machining metal matrix composites,” Surface and Coating Technology, vol. 179, no. 2-3,pp. 349-355 February 2004.
[8] Patel P.R, Patel V. A “Study on machinability of metal matrix composite in turning: A Review, Journal of information knowledge and research in mechanical engineering, ISSN 0975-668X NOV 11 to OCT 12 Volume -02, ISSUE-01
[9] N. Chawla, K.K Chawla, “Metal-matrix composites in ground transportation,” J. of Manufacturing, vol. 58, no. 11, pp. 67-70 November 2006.
[10] AutarK.Kaw. Mechanics of composite Material. Taylor & Francis Group, 2006.
[11] M.N. Wahab, A.R. Daud and M.J. Ghazali, “Preparation and characterization of stir cast-aluminum Nitride Reinforced Aluminum Metal Matrix Composites,” Int. Journal of Mechanical and Materials Eng., vol. 4, no. 2, pp. 115-117, 2009.
[12] D. Kent, G.B. Schaffer, T.B. Sercombe, J. Drennan, “A novel method for the production of aluminium nitride,” ScriptaMaterialia, vol. 54, no. 12, pp. 2125-2129, June 2006.
[13] J. Haibo, K. Chen, Z. Heping, S. Agayhopoulos, O. Fabrichnaya, J.M.F. Ferreira, “Direct nitridation of molten Al (Mg, Si) alloy to AlN,” Journal of Crystal Growth, vol. 281, no. 2-4, pp. 639-645, August 2005.
[14] V.V. Roa, M.V. Krishna Murthy, J. Nagaraju, “Thermal conductivity and thermal contact conductance studies on Al2O3/Al-AlN metal matrix composite,” Composite Science and Technology J., vol. 64, no. 16, pp. 2459-2462, December 2004.
[15] S. Shima, S. Hayashi, “Preparation of monolithic AlN and composite TiN-AlN powders and films from precursors synthesized by electrolysis,” Materials Science and Engineering: BJ., vol. 122, no. 1, pp. 34-40, August 2005.
[16] R. Venkatesh, A.M. Hariharan, N. Muthukrishnan, “Machinability Studies of Al/SiC/ (20p) MMC by Using PCD Insert (1300 grade),” in Proc. of the World Congress on Engineering, vol. 2, London, 2009.
[17] S.H. Tomadi, J.A. Ghani, Che Hassan C.H, A.R. Daud, “Effect of Machining Parameter On Tool Wear and Surface Roughness of Al-AlN Reinforce MMC In End Milling Machining,” Journal Engineering E-transaction, Electronic Journal of University Malaya (EJUM.), 2011.
[18] A. G. Jaharah, Mohd Nor AzmiMohdRodzi, A. Abdul Rahman, MohdNizam Ab. Rahman and C. H. Che Hassan, “Machinability of FCD 500 ductile cast iron using coated carbide tool in dry machining condition,” Int. Journal of Mechanical and Material Engineering, vol. 4, no.3, pp. 279-284, 2009.
[19] R.B. Gundlach, J. Janowak, “Metal Progress,”International Journal of Machine Tools & Manufacture, vol. 4, pp. 1003-1014, 1985.
[20] R. Komanduri, J. Desai, “Tool Master” Encyclopedia of Chem. Technology. vol. 23, pp. 455- 642.
[21] K. A. Venugopal, R. Tawadel, P. G. Prashanth, S. Paul, A. B. Chattopadhyay, “Turning of titanium alloy with TiB2-coated carbides under cryogenic cooling,” in Proc. of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, vol. 217, no. 12, pp. 1697-1707, 2003.
[22] A. Mubarak, E. Hamzah et al., “The effect of the nitrogen gas flow rate on the properties of TiN-Coated high-speed steel (HSS) using cathodic ARC evaporation physical vapor deposition (PVD) technique,” Surface Review and Letters, vol. 12, no. 4, pp. 631-643August2005.
[23] S. Kalpakjian, S.R. Rchmid, Manufacturing Engineering and Technology. International Ed. USA: Prentice Hall, 2006.
[24] G. Boothroyd, W.A.Knight, Fundamental Machining and Machine Tool. Belmont, USA: Taylor and Francis CRC, 2006.