Finite element simulation of machining metal matrix composite AlSiC

Manan, Muhammad Zubair (2021) Finite element simulation of machining metal matrix composite AlSiC. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Over the years, composites of the metal matrix (MMCs) have become important composite materials. Due to their excellent characteristics, the particle enhanced aluminium MMCs have acquired great demand. Due to the existence of harder abrasive refinement particles that are harder than the cutting tools, these materials are regarded as difficult to process. There are many inherent difficulties, such as high cutting temperature, caused by the lack of marketing of a specialised cutter for machining MMC materials. A novel geometrical design for the processing of metal matrix composites (MMCs) materials has been developed to address this issue. The objective of this study is to improve geometric cutter characteristics, which can manufacture MMCs efficiently. In this study, effects of cutter geometric characteristics such as helix angle, rake angle, clearance angle and flute number on surface roughness, tool wear, temperature and strength were studied to optimise cutter geometric features. Temperature and stress are the output response to be considered. By optimising the geometrical characteristics of the cutting tool, the researchers have concentrated on temperature and stress reduction. However, the analysis of studies using the Finite Element Method (FEM) is restricted. A major impact on temperature and stress values lies in the cutter geometrical properties, particularly rake angle, helix angle, clearance angle, and number of flutes. In addition, statistical analysis was used to establish the connection for each reaction, i.e., temperature and stress associated with cutter geometry. The optimization of the cutter shape that can efficiently machine MMC at low temperature are the combination of 15º rake angles, 6º clearance angles, 40º helix angles and 4 flutes. The combination of rake angle 5º, clearance angle 17º, helix angle 60º and flute number 2 has, meanwhile, been selected to optimize cutter shape that creates the lowest stress value.

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