Scipediacontent at 14:29, 10 April 2017

2017-04-10T14:29:48Z

Scipediacontent: Scipediacontent moved page Draft Content 562123771 to Das et al 2016a

2017-04-10T14:23:26Z

Scipediacontent moved page Draft Content 562123771 to Das et al 2016a

Scipediacontent: Created page with "==Abstract== With the major application of MMCs, it is thus necessary to develop an appropriate technology for their efficient machining. Milling is the most common and versa..."

2017-04-10T14:14:36Z

Created page with "==Abstract== With the major application of MMCs, it is thus necessary to develop an appropriate technology for their efficient machining. Milling is the most common and versa..."

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 The first generation of aluminium based composite materials having ceramic reinforcements are found to reveal good quality strength to weight ratio and better corrosion resistance. Currently, the research consideration is directed toward the hybrid composites having more than one reinforcing phase [[#bib0010|[1]]] . An ample spread application of these second generation MMCs are not possible without solution to the problems related to cutting [[#bib0015|[2]]]  and [[#bib0020|[3]]] .
-Manna and Bhattacharyya [[#bib0025|[4]]]  have investigated the effect of cutting speed, feed and depth of cut on wear of the cutting tool and built-up edge formation during the turning operation of Al–SiC particulate composite, using a rhombic uncoated tool of carbide material. However, less amount of built up edge formation was found at a lower depth of cut and at higher cutting speed. Ciftci et al. [[#bib0030|[5]]]  have examined the effect of SiC particulate size on the wear of the tool and surface finish with cubic boron nitride (CBN) tool insert at constant depth of cut, feed and at varying cutting speeds. It was suggested that for 30 µm and 45 µm size of SiC in aluminium metal matrix, optimum cutting speed was achieved at 150 m/min. For better size of SiC reinforcements (110 µm), CBN tool was not found appropriate for turning operation. Chambers [[#bib0035|[6]]]  have found that the performance of PCD insert was significantly superior than carbides insert while turning Al
+Manna and Bhattacharyya [[#bib0025|[4]]]  have investigated the effect of cutting speed, feed and depth of cut on wear of the cutting tool and built-up edge formation during the turning operation of Al–SiC particulate composite, using a rhombic uncoated tool of carbide material. However, less amount of built up edge formation was found at a lower depth of cut and at higher cutting speed. Ciftci et al. [[#bib0030|[5]]]  have examined the effect of SiC particulate size on the wear of the tool and surface finish with cubic boron nitride (CBN) tool insert at constant depth of cut, feed and at varying cutting speeds. It was suggested that for 30 µm and 45 µm size of SiC in aluminium metal matrix, optimum cutting speed was achieved at 150 m/min. For better size of SiC reinforcements (110 µm), CBN tool was not found appropriate for turning operation. Chambers [[#bib0035|[6]]]  have found that the performance of PCD insert was significantly superior than carbides insert while turning Al&mdash;5Mg reinforced with a combination of 5 vol.% saffil and 15 vol.% SiCp. Looney et al. [[#bib0040|[7]]]  have performed a series of turning operations on the Al–25%SiC metal matrix composite using CBN, carbide, and silicon nitride inserts. From these inserts, cubic boron nitride insert has formed the best cutting, and silicon nitride inserts was the worst among all. El-Gallab and Sklad [[#bib0045|[8]]]  have determined the quality of the surface of Al–20%SiC composite in high speed turning under different cutting parameters. It was found in their investigation that the polycrystalline diamond tools (PCD) exhibited appropriate cutting tool life as when being compared with coated carbide tools and alumina.
-[[Image:draft_Content_562123771-sbnd|center|px|single bond]]
 Mg reinforced with a combination of 5 vol.% saffil and 15 vol.% SiCp. Looney et al. [[#bib0040|[7]]]  have performed a series of turning operations on the Al–25%SiC metal matrix composite using CBN, carbide, and silicon nitride inserts. From these inserts, cubic boron nitride insert has formed the best cutting, and silicon nitride inserts was the worst among all. El-Gallab and Sklad [[#bib0045|[8]]]  have determined the quality of the surface of Al–20%SiC composite in high speed turning under different cutting parameters. It was found in their investigation that the polycrystalline diamond tools (PCD) exhibited appropriate cutting tool life as when being compared with coated carbide tools and alumina.
 Ding et al. [[#bib0050|[9]]]  has investigated the machining behaviour of Al–SiC MMC using the PCBN and the PCD tools. Surface cracking was observed at the flank face surfaces of the cutting tools; intergranular fractures were observed on the rake faces. The PCD inserts performance was better than the PCBN inserts. Yanming and Zehua [[#bib0055|[10]]]  reported the mechanism of cutting tool wear during the machining of Al–SiC composite. The cutting tool flank surface was being affected by abrasive wear and it was found that the carbide tool was appropriate for the fine size of SiC reinforced composite. It was also seen that the size of the reinforcement and the volume fraction played a great role in the cutting tool life.
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 Muthukrishnan et al. [[#bib0060|[11]]]  reported that better quality of surface finish in turning of A356/SiC MMCs could be achieved by means of medium grade PCD 1500 inserts with less power utilization at the elevated cutting speed. BUE formation was seen on the tip of cutting tools at lower cutting speed. Pramanik et al. [[#bib0065|[12]]]  have explained the effect of factors, such as tool particle connections, difference in strain, thermal softening, and work hardening, on the variation of cutting forces for metal matrix composites and its alloy. Tamer et al. [[#bib0070|[13]]]  investigated the influence of machining parameters such as cutting speed, feed and depth of cut on the cutting tool wear and surface roughness of AlSi<sub>7</sub> Mg<sub>2</sub>  reinforced with 5, 10 and 15 wt.% of SiCp. Mahamani [[#bib0075|[14]]]  has optimized the cutting parameters in machining of in situ Al–5Cu–TiB<sub>2</sub>  composite using uncoated tungsten carbide inserts. Anandakrishnan and Mahamani [[#bib0080|[15]]]  have studied the machinability of in situ Al–6061–TiB2 MMCs. The flank wear rate, cutting force, and surface roughness were found to be higher with a higher value of depth of cut.
-Rai et al. [[#bib0085|[16]]]  have studied the cutting force development and chip formation while doing shaping operation of Al–TiC composites and compared them with Al–TiAl<sub>3</sub>  composite and Al
+Rai et al. [[#bib0085|[16]]]  have studied the cutting force development and chip formation while doing shaping operation of Al–TiC composites and compared them with Al–TiAl<sub>3</sub>  composite and Al&mdash;Si alloys. There was improvement in the quality of the surface machined with the increased quantity of TiC reinforcing particles in the composite. The cutting force developed while machining Al–TiC metal matrix composite was lower than the cutting force developed while machining Al–TiAl<sub>3</sub>  composite and Al&mdash;Si alloy. Kumar et al. [[#bib0090|[17]]]  have studied the feasibility, dry turning characteristics of Al–4.5%Cu/TiC composites using uncoated ceramic inserts. The influence of the input process parameters on the surface roughness and cutting force was observed. BUE formation was found lower at higher cutting speeds and was found higher at lower cutting speeds. Razavykia et al. [[#bib0095|[18]]]  evaluated machining process parameters and the modifier element effects on the cutting force and the surface roughness in the dry turning of the Al–Mg<sub>2</sub> Si in-situ MMC. The addition of the Bi element as modifier reagent results in the lower cutting force and the lower surface roughness. Kumar and Chauhan [[#bib0100|[19]]]  also investigates the effect of the cutting speed, feed, approach angle on the surface roughness of Al7075 ceramic composite (10% SiC) and Al7075 hybrid composite (7%SiC and 3% graphite). It was found that in the turning operation of both the composite surface roughness of the hybrid, composite was less than the ceramic composite. Karabulut [[#bib0105|[20]]]  has fabricated AA7039/Al<sub>2</sub> O<sub>3</sub>  MMC by using powder metallurgy technique and found that material structure was the most effective factor in affecting the cutting force, and surface roughness. The milling test was being performed based on the Taguchi design of experiment. Shoba et al. [[#bib0110|[21]]]  also investigated the effect of the cutting speed, feed, and depth of cut on cutting force. A comparison study was performed for the reinforced and unreinforced composites, and the result shows that cutting force decreases with the increase in the weight percentage of the reinforcements.
-[[Image:draft_Content_562123771-sbnd|center|px|single bond]]
 Si alloys. There was improvement in the quality of the surface machined with the increased quantity of TiC reinforcing particles in the composite. The cutting force developed while machining Al–TiC metal matrix composite was lower than the cutting force developed while machining Al–TiAl<sub>3</sub>  composite and Al
-[[Image:draft_Content_562123771-sbnd|center|px|single bond]]
 Si alloy. Kumar et al. [[#bib0090|[17]]]  have studied the feasibility, dry turning characteristics of Al–4.5%Cu/TiC composites using uncoated ceramic inserts. The influence of the input process parameters on the surface roughness and cutting force was observed. BUE formation was found lower at higher cutting speeds and was found higher at lower cutting speeds. Razavykia et al. [[#bib0095|[18]]]  evaluated machining process parameters and the modifier element effects on the cutting force and the surface roughness in the dry turning of the Al–Mg<sub>2</sub> Si in-situ MMC. The addition of the Bi element as modifier reagent results in the lower cutting force and the lower surface roughness. Kumar and Chauhan [[#bib0100|[19]]]  also investigates the effect of the cutting speed, feed, approach angle on the surface roughness of Al7075 ceramic composite (10% SiC) and Al7075 hybrid composite (7%SiC and 3% graphite). It was found that in the turning operation of both the composite surface roughness of the hybrid, composite was less than the ceramic composite. Karabulut [[#bib0105|[20]]]  has fabricated AA7039/Al<sub>2</sub> O<sub>3</sub>  MMC by using powder metallurgy technique and found that material structure was the most effective factor in affecting the cutting force, and surface roughness. The milling test was being performed based on the Taguchi design of experiment. Shoba et al. [[#bib0110|[21]]]  also investigated the effect of the cutting speed, feed, and depth of cut on cutting force. A comparison study was performed for the reinforced and unreinforced composites, and the result shows that cutting force decreases with the increase in the weight percentage of the reinforcements.
 The multi-output optimization problems could be solved by using different methods such as grey relational analysis (GRA), genetic algorithm (GA), artificial neural network (ANN), response surface methodology (RSM) and fuzzy logic [[#bib0115|[22]]] .
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 Soepangkat and Pramujati applied integrated approach comprising of GRA and fuzzy-logic for optimizing wire EDM of AISI D2 steel for minimizing surface roughness and layer thickness [[#bib0175|[34]]] . Related optimization techniques have been effectively utilized in a variety of manufacturing processes, which are mostly carried out under complex and uncertain environment [[#bib0125|[24]]] , [[#bib0180|[35]]] , [[#bib0185|[36]]] , [[#bib0190|[37]]]  and [[#bib0195|[38]]] .
 Even though a very few research works have been carried out to study the influence of CNC milling parameters on different quality and productivity aspects, it is very necessary to establish optimal parametric combination with the intention of obtaining improved machined surface. Thus, the present work is focused on optimization of CNC milling machining parameters of Al–4.5%Cu–TiC metal matrix composite using grey-fuzzy analysis. The experimental work is done on the basis of Taguchis L<sub>25</sub>  orthogonal array. The essential input milling parameters selected are cutting speed, feed and depth of cut, and the outputs considered are surface roughness and cutting force. For minimizing the values of all the performance characteristics, an optimal combination of input process parameters are required.
 ==2. Experimental description==

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Das et al 2016a - Revision history

Scipediacontent at 14:29, 10 April 2017

Scipediacontent: Scipediacontent moved page Draft Content 562123771 to Das et al 2016a

Scipediacontent: Created page with "==Abstract== With the major application of MMCs, it is thus necessary to develop an appropriate technology for their efficient machining. Milling is the most common and versa..."