Abstract
This paper reports the machinability studies on aluminium hybrid composites of different compositions by using abrasive water jet machining process. In this study, aluminum hybrid metal matrix composites (HMMCs) with 5%, 10% and 15% Boron Carbide (B4C) and 5% Zirconium Silicate (ZrSiO4) with Al 6063 were fabricated using stir casting method. The cutting experiments were carried out by varying the water jet pressure, traverse rate, abrasive flow rate, and abrasive mesh size, and their effects on depth of cut (DOC), material removal rate (MRR) and surface roughness (Ra) were analyzed. Experiments were designed by using Box-Behnken response surface design, and the results were analyzed with response surface plots. In addition, the detailed surface evaluation studies were carried out by using 3D surface topography and morphology descriptions. Regression equations were developed to determine the significant factors in HMMCs. ANOVA test results were established for checking model adequacy in HMMCs with various responses. The results indicated that the proportion rate of B4C with ZrSiO4 ceramic particles in Al6063 affects the machinability and surface quality features. Also, the abrasive mesh size was found to be the responsible factors for higher DOC, MRR and lower Ra in HMMCs. The machined surface of hybrid composites shows the ploughing effect and cavities indicating both ductile and brittle fracture mechanisms.
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The datasets generated during the current study are available from the corresponding author on reasonable request.
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Authors acknowledge the M/s. Sivasakthi water jet cutting pvt ltd, Chennai for experimental support.
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P. Thamizhvalavan – Conceptualization, Investigation, Software; N. Yuvaraj – Methodology, Writing-Original Draft & Review Editing; S. Arivazhagan – Validation, Supervision.
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Thamizhvalavan, P., Yuvaraj, N. & Arivazhagan, S. Abrasive Water Jet Machining of Al6063/B4C/ZrSiO4 Hybrid Composites: a Study of Machinability and Surface Characterization Analysis. Silicon 14, 1093–1121 (2022). https://doi.org/10.1007/s12633-020-00888-2
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DOI: https://doi.org/10.1007/s12633-020-00888-2