Optimization of thrust force, torque, and tool wear in drilling of coir fiber-reinforced composites using Nelder–Mead and genetic algorithm methods

Machining of composite materials is an important and current topic in modern researches on manufacturing processes. Determination of optimal cutting parameters is one of the most important elements in the machinability study of composites. Optimization has significant practical importance particularly for operating the machineries. In order to increase the accuracy of drill holes, the tool must be in good condition always as much as possible. To achieve good condition of tool, the optimization of machining parameters like drill bit diameter, spindle speed, and feed rate are mandatory. The objective of this paper is to study the effect of these process parameters on thrust force, torque, and tool wear in drilling of coir fiber-reinforced composites. The optimal settings of the parameters were determined through experiments planned, conducted, and analyzed using the Box–Behnken design, Nelder–Mead, and genetic algorithm methods. This paper also aimed to increase the cutting condition of tool, i.e., minimization of tool wear by applying the optimized input parameters using Nelder–Mead and genetic algorithm techniques.     

Fabrication of copper–TiC–graphite hybrid metal matrix composites through microwave processing

The significant requirements such as wear resistance and better tribological properties in addition to good electrical conductivity necessitate the development of copper-based advanced metal matrix composites for electrical sliding contact applications. Though the addition of graphite to copper matrix induces self-lubricating property, the strength of the composite reduces. The improvement in the strength of the composite can be achieved by reinforcing harder ceramic particles such as SiC, TiC, and Al₂O₃. In this paper, the development of hybrid composite of copper metal matrix reinforced with TiC and graphite particles through microwave processing was investigated. The effects of TiC (5, 10, and 15 vol.%) and graphite (5 and 10 vol.%) reinforcements on physical and mechanical properties of microwave-sintered copper–TiC–graphite hybrid composites are discussed in detail. Micrographs show the uniform distribution of reinforcements in copper matrix. Microwave-sintered composites exhibited higher relative density, sintered density, and hardness compared with conventionally sintered ones.     

Influence of turning parameters on the machinability of homogenized Al–Cu/TiB2 in situ metal matrix composites

The increasing demand for high-strength and lightweight materials in automobile, defense, and aerospace applications necessitates the development of new composite materials and their machinability studies with wide spectrum. In this aspect, an attempt has been made to investigate the machinability characteristics of homogenized Al–Cu/TiB₂ in situ metal matrix composites. The effect of parameters, such as cutting speed, feed, and depth of cut, on performance measures, such as cutting force and surface roughness, were investigated during turning operations. As a secondary objective, the built-up edge (BUE) and chip formation are also examined. Experimental results show that better surface finish is obtained at higher cutting speed and low feed. BUE formation is observed only at low cutting speed. The chip breakability is improved due to the presence of reinforcement.     

Experimental investigation and optimization of EDM process parameters for machining of aluminum boron carbide (Al–B4C) composite

This study investigates the effect of electric discharge machining (EDM) process parameters [current, pulse-on time (T_on), pulse-off time (T_off) and electrode material] on material removal rate (MRR), electrode wear rate (EWR) and surface roughness (SR) during machining of aluminum boron carbide (Al–B₄C) composite. This article also summarizes a brief literature review related to aluminum metal matrix composites (Al-MMCs) based on different process and response parameters, work and tool material along with their sizes, dielectric fluid and different optimization techniques used. The MMC used in the present work is stir casted using 5% (wt) B₄C particles of 50 micron size in Al 6061 metal matrix. Taguchi technique is used for the design of experiments (L₉-orthogonal array), while the experimental results are analyzed using analysis of variance (ANOVA). Response table for average value of MRR, EWR and SR shows that current is the most significant factor for MRR and SR, while electrode material is most important for EWR. ANOVA also confirms similar results. It is also observed that the optimum level of process parameters for maximum MRR is A₃B₁C₃D₃, for minimum EWR is A₁B₂C₃D₁, and for SR is A₁B₃C₃D₃.     

Experimental and theoretical analysis of friction stir welding of Al–Cu joints

This paper presents a study of friction stir welding of aluminium and copper using experimental work and theoretical modelling. The 5083-H116 aluminium alloy and pure copper were successfully friction-stir-welded by offsetting the pin to the aluminium side and controlling the FSW parameters. A theoretical analysis is presented along with key findings. The process temperatures are predicted analytically using the inverse heat transfer method and correlated with experimental measurements. The temperature distribution in the immediate surroundings of the weld zone is investigated together with the microstructures and mechanical properties of the joint. This was supported by a finite element analysis using COMSOL Multiphysics. In this study, two rotational speeds were used and a range of offsets was applied to the pin. The microstructure analysis of the joints was undertaken. This revealed some particles of Cu inclusion in the nugget zone. The energy dispersive spectroscopy showed a higher diffusion rate of aluminium towards the interface while copper maintained a straight base line.     

Mechanism of material removal during tribological behaviour of aluminium matrix (Al–Zn–Mg–Cu) composites

In the present study an attempt is made to synthesise Al–Zn–Mg–Cu alloy–SiC particle reinforced composite using liquid metallurgy route and to characterize the composites in terms of microstructure and sliding wear. It is to be noted that seizure pressure is enhanced by 37.5% due to the addition of 10 wt% of SiC particles in aluminium alloy. The wear mechanism is dictated by the formation and stability of oxide layer, mechanically mixed layer (MML) and subsurface deformation and cracking. There is also mutual transfer of pin surface and counter surface materials. The critical load at which MML gets removed is also examined. These phenomenon are represented schematically in this paper and the wear mechanism is explained.     

EDM of hybrid Al–SiCp–B4Cp and Al–SiCp–Glassp MMCs

Hybrid metal matrix composites are a class of material system, with two or more discrete particulate reinforcement. Notwithstanding their superior properties, their widespread application is constrained by the difficulty in machining them. Non-conventional processes such as electrical discharge machining can be applied to machine such composites. This work reports on the application of EDM to machine cast aluminum–silicon carbide–boron carbide and cast aluminum–silicon carbide–glass hybrid metal matrix composites and how the metal removal rate and surface finish vary in response to the various EDM parameters     

Exploring the hybrid metal extrusion and bonding process for butt welding of Al–Mg–Si alloys

The hybrid metal extrusion and bonding (HYB) process is a new solid-state joining technique developed for aluminum alloys. By the use of filler material addition and plastic deformation sound joints can be produced at operating temperatures below 400 °C. The HYB process has the potential to compete with commonplace welding technologies, but its comparative advantages have not yet been fully explored. Here, we present for the first time the results from an exploratory investigation of the mechanical integrity of a 4-mm AA6082-T6 HYB joint, covering both hardness, tensile and Charpy V-notch testing. The joint is found to be free from defects like pores, internal cavities and kissing bonds, yet a soft heat-affected zone (HAZ) is still present. The joint yield strength is 54% of that of the base material, while the corresponding joint efficiency is 66%. The indications are that the HYB process may compete or even outperform conventional welding techniques for aluminum in the future after it has been fully developed and optimized.     

Investigations of flank wear, cutting force, and surface roughness in the machining of Al-6061�CTiB2 in situ metal matrix composites produced by flux-assisted synthesis

This paper presents the results of an experimental investigation on the machinability of in situ Al-6061?CTiB₂ metal matrix composite (MMC) prepared by flux-assisted synthesis. These composites were characterized by scanning electron microscopy, X-ray diffraction, and micro-hardness analysis. The influence of reinforcement ratio of 0, 3, 6, and 9?wt.% of TiB₂ on machinability was examined. The effect of machinability parameters such as cutting speed, feed rate, and depth of cut on flank wear, cutting force and surface roughness were analyzed during turning operations. From the test results, we observe that higher TiB₂ reinforcement ratio produces higher tool wear, surface roughness and minimizes the cutting forces. When machining the in situ MMC with high speed causes rapid tool wear due to generation of high temperature in the machining interface. The rate of flank wear, cutting force, and surface roughness are high when machining with a higher depth of cut. An increase in feed rate increases the flank wear, cutting force and surface roughness.     

Wear behaviour of in situ Cu–Al2O3 composites produced by internal oxidation of as cast alloys

Abstract

In the present study, the wear behaviour of Cu–Al₂O₃ composites and Cu–Al alloys has been investigated. The experiment involved casting of Cu–Al alloys with 0·37, 1, 2 and 3 wt-% of aluminium under inert gas atmosphere. The composites were produced by internal oxidation of alloys at 950°C for 10 h in presence of Fe₂O₃ and Al₂O₃ powders mixture. The microstructures of composites were studied using SEM and atomic force microscopy. To identify wear behaviour of specimens, dry sliding pin-on-disk wear tests were conducted according to ASTM G99-95a standard. The normal loads of 20, 30, and 40 N were applied on specimens during wear tests. The sliding speed and distances were selected as 0·5 m s^–1 and 500, 1000 and 1500 m respectively. To specify the wear mechanisms, the worn surfaces of composites were examined by SEM equipped with EDX. According to wear test results, increasing applied load and sliding distance leads to more volume loss in all specimens. Composites represent better wear resistance in comparison to alloys. Additionally, increasing the volume fraction of alumina particles in composites enhances the wear resistance, especially under high applied load. The wear mechanisms are mainly abrasion, oxidation and delamination.     

Effect of matrix/reinforcement particle size ratio (PSR) on the mechanical properties of extruded Al–SiC composites

This paper studied the combined effects of matrix-to-reinforcement particle size ratio (PSR) and SiC volume fraction on the mechanical properties of extruded Al–SiC composites. A powder metallurgy technique (PM) of cold pressing at 500 MPa followed by hot extrusion at 580 °C was adopted to produce Al/SiC composite. Aluminum powder of size 60 μm and silicon carbide with different sizes, i.e., 50, 20, and 8 μm, were used. Three different volume fractions of SiC were employed, i.e., 5, 10, and 15 %, for each investigated size using a constant extrusion ratio of 14.36. The effect of matrix-to-reinforcement PSR on the reinforcement spatial distribution, fabricability, and resulting mechanical properties of a PM-processed Al/SiC composite were investigated. It has been shown that small ratio between matrix to reinforcement particle size resulted in more uniform distribution of the SiC particles in the matrix. As the PSR increases, the agglomerations and voids increase and the reinforcement particulates seem to have nonuniform distribution. In addition, the agglomerations increased as the volume fraction of the SiC increased. It has also been shown that homogenous distribution of the SiC particles resulted in higher yield strength, ultimate tensile strength, and elongation. Yield strength and ultimate tensile strength of the composite reinforced by PSR (1.2) are higher than those of composite reinforced by PSR (7.5), while the elongation shows opposite trend with yield strength and ultimate tensile strength.     

Experimental analysis of coating layer behavior of Al–Si-coated boron steel in a hot bending process for IT applications

The utilization of high-strength steel for automotive structural parts has increased since the oil crisis in the 1970s owing to its high strength and potential for weight reduction. Because of the limited formability of high-strength steels, automotive components are increasingly produced through hot press forming. In some instances, high-strength steel sheets are coated with an Al–Si layer in order to prevent scaling of components during hot press forming, and this can increase their reliability with a view to the dimensional accuracy and stress distribution when they are in service. In this contribution, the coating degradation mechanisms of Al–Si-coated boron steel after the hot bending process are reported. The issues related to coating degradation during hot press forming are critically reviewed at different positions on a part that was subject to hot bending. In addition, the hardness and friction coefficient were tested by a nano-indenter at various positions. The relationship between the experimental parameters and coating layer properties is also reported. It is concluded that the bending deformation affected the coating layer behavior the most.     

The abrasive wear resistance of TIC and (Ti,W)C-reinforced Fe–17Mn austenitic steel matrix composites

Pin-on-disc dry sliding wear tests have been carried out to study the wear behaviour of 10 vol% TiC and (Ti,W)C-reinforced Fe–17Mn austenitic steel matrix composites. The composites have been synthesized in situ by means of conventional melting and casting route. It has been observed that the abrasive wear resistance of the composites is higher than that of their unreinforced Fe–17Mn austenitic steel. Compared with the TiC-reinforced composite, the abrasive wear resistance of the (Ti,W)C-reinforced composite is better. The abrasive wear resistance and coefficient of friction of both reinforced and unreinforced materials decrease as the load increases.     

Application of general regression neural network (GRNN) for indirect measuring pressure loss of Herschel–Bulkley drilling fluids in oil drilling

Experimental measurements of the pressure losses in a well annulus are costly and time consuming. Pressure loss calculations in annulus is generally conducted based on an extension of empirical correlations developed for Newtonian fluids and extending pipe flow correlations. However, correct estimation of pressure loss of non-Newtonian fluids in oil well drilling operations is very important for optimum design of piping system and minimizing the power consumption. In this paper, a general regression neural network (GRNN) was applied to predict the pressure loss of Herschel–Bulkley drilling fluids in concentric and eccentric annulus. Experimental data from literature were used to train the GRNN for estimating pressure losses in annulus. The predicted values using GRNN closely followed the experimental ones with an average relative absolute error less than 6.24%, and correlation coefficient (R) of 0.99 for pressure loss estimation.     

Analysis of dry sliding friction and wear behaviour of AA6351–SiC–B4C composites using grey relational analysis

Abstract

This paper describes the multifactor based experiments that are applied to investigate the dry sliding wear system of aluminium matrix alloy (AA6351) with 5 wt-% silicon carbide (SiC), 5 wt-% and 10 wt-% of boron carbide (B₄C) reinforced metal matrix composites (MMCs). Stir casting route was adopted to prepare the composites and the tribological experiments were carried out on pin-on-disc type wear machine. The effects of parameters like applied load, sliding velocity, wt-% of B₄C on the dry sliding wear and frictional coefficient of aluminium MMCs using grey relational analysis (GRA) are reported. The orthogonal array with L9 layout and analysis of variance were used to investigate the influence of the parameters. It is observed that the dry sliding friction and wear behaviour of the composites are influenced by the applied load, sliding velocity and wt-% of B₄C with a contribution of 60·82%, 21·72% and 14·28% respectively. The optimal design parameters were found by grey relational grade and a good agreement was observed for 95% level of confidence.     

A comparison of the reciprocating sliding wear behaviour of steel based metal matrix composites processed from self-propagating high-temperature synthesised Fe–TiC and Fe–TiB2 masteralloys

Steel matrix particulate composites were processed by direct addition of various powders to molten medium carbon steel. Fe–TiC and Fe–TiB₂ powders were produced using a self-propagating high-temperature synthesis (SHS) reaction and consisted of a dispersion of fine TiC (5–10 μm) and TiB₂ particles (2–5 μm), respectively in an iron binder.Addition of the Fe–TiC powder to the steel resulted in the formation of a metal matrix composite containing a homogeneous dispersion of TiC particles. However, addition of the Fe–TiB₂ powder resulted in the formation of a parasitic Fe₂B phase and TiC within the steel microstructure. In response to this an SHS masteralloy composed of Fe–(50% TiB₂+50%Ti) was manufactured which, when added to steel, prevented the formation of Fe₂B and resulted in a composite containing a mixture of TiB₂ and TiC particles.Dry reciprocating sliding wear behaviour of the three composite materials and their unreinforced counterpart was investigated at room temperature against a white cast iron counterface. Relative wear behaviour of the materials varied as a function of load. In all cases, the composite manufactured by addition of Fe–TiB₂ (yielding Fe₂B and TiC phases in the steel) exhibited wear rates greater than three times that of the unreinforced alloy. However, improvements in wear resistance over the base steel of up to two and a half times were observed with the other composites where the desired TiC and/or TiB₂ phases were retained in the steel. Scanning electron microscopy has been used to interpret wear behaviour in relation to both the as-cast microstructures of the composites and the wear scar microstructures observed.     

Wear mechanisms of K2Ti4O9 whiskers reinforced Al20Si aluminum matrix composites with lubrication of water and tetradecane

The tribological properties of K₂Ti₄O₉ whisker reinforced Al20Si aluminum matrix composites were investigated in a mode of low amplitude reciprocal sliding. The ball-on-disk tests were performed at applied loads of 20–100 N and sliding velocity of 0.09 m s⁻¹. The water lubricated composites demonstrated higher wear resistance and friction coefficient than the tetradecane lubricated composites did. The main wear mechanism is microgrooving at low applied loads and tribochemical wear at high applied loads for the pairs lubricated with water, microgrooving at all test loads for the pairs lubricated with tetradecane.