Abstract

This paper presents a study on chip formation in the milling process of Al-Si/10% AlN Metal Matrix Composite (MMC). It focuses on the effect of cutting parameters on the formation of the chip. Al-Si/10% AlN MMC reinforced with 10% AlN particle is a new-generation material that is suitable for manufacturing automotive and aerospace components. Several advantageous characteristics of this material include low density, light weight, high strength, high hardness and high stiffness. The milling process was carried out at dry cutting conditions by using TiN-coated carbide tool insert, which was developed by Standards and Industrial Research Institute of Malaysia (SIRIM). The machining parameters were as follows: a constant cutting speed of 230 m/min, feed rates of 0.4, 0.6 and 0.8 mm/tooth and cutting depths of 0.3, 0.4 and 0.5 mm. The analysis of the chip formation was performed using a video microscope (Sometech, SV-35). The chips were formed because of the shear between the work pieces and the cutting chips during dry milling of Al-Si/10% AlN MMC. These chips were small, short and discontinuous with outer face cracks.

Keywords:

Al-Si/10% AlN Metal Matrix Composite (MMC), chip formation, milling process, TiN,

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The authors have no competing interests.

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