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Study of Thrust Force in Drilling Al / SiC - Nano TiO2
Metal Matrix Composites Using Response Surface Method
N. Prem kumar1*, N. Mani2 & K. Palanikumar2
1Research Scholar,
Department of Mechanical Engineering
Anna University, Sri Sai Ram Institute of Technology, India, [email protected]
2Department of Mechanical Engineering,
Sri Sai Ram Engineering College, India
Abstract
Drilling process is ultimate and prime route in component assembling. It should
give a good interlaminer property and dimensionally balanced. Due to imperfect
drilling, assembly of components is difficult and further leads to lower
performance. This paper discusses the outcome of drilling parameter such as drill
diameter, speed of spindle and feed rate produces thrust force on Al / SiC with
TiO2 Nano Composite. Thrust force is a predominant and inevitable parameter in
hole making operation. Titanium Nitride coated twist drill bit of 6, 8 and 10mm
diameters are used. TiN coated HSS twist drills showed the better performance
with reference to the thrust force. The current study deals with, employing Box-
Behnken design using response surface methology for optimizing the drilling
parameters on the Al6061-SiC/Nano TiO2 composite. The effectiveness of various
parameters against thrust force of Al6061-SiC/ Nano TiO2 composites has been
evaluated by surface plots and three-dimensional graphs. The result indicates that
thrust force is increases due to increasing of feed rate and drill diameter and
reduced by increasing the spindle speed. Further, investigation was performed by
using SEM and AFM in analyzing of the surface of drilled area of given composite.
Keywords: Drilling, Thrust force, SEM, EDAX, Titanium Nitride coated drill
bits, Al-SiC/TiO2 nano powder and Box–Behnken experimental design
1. Introduction
In Recent Trend, Metal Matrix Nano composites proves significant applications in
automotive, aero, chemical industries, structural application and diversional fields required
deep analysis of machined surface, which determine the material to overcome rigorous
condition of stress, high temperature, and corrosion. It gives good mechanical properties
such as hardness, density, tensile strength, electrical conductivity, thermal conductivity,
ductility and wear resistance. Matrix undergoes a small elastic strain which forms a
microcracks and growth of voids in the composites [DI ZHANG, KENJIRO SUGIO et al.
2008]. The flow of aluminum matrix (high temperature) embedded with reinforcement
materials, usually ceramic with equal dimension in all direction or an aspect ratio less than
4 [RAMULU M et al. 2002]. The presence of silicon carbide in the matrix material
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directly influences the behavior of the material in aspect of heat treatment and its allied
processes. Silicon carbide act as a driving force for the utilization of metal matrix
composites by its performance, low cost and environmental benefits [GAITONDE V N et
al. 2008]. The factor which affects the TiO2 during composite production are interfacial
bonding and crystalline structure [TOSUN N et al. 2006]. Drilling characteristics of MMC
is distinct from the metal drilling, due to their anisotropic and inhomogeneous in nature.
PALANIKUMAR K et al. 2014 has investigated and analyzed the different cutting
parameter of hybrid MMC that concludes the thrust force is influenced by feed rate in
drilling operation. RAJMOHAN T et al. 2012 investigated by using hybrid metal matrix
composite appropriate model was developed for predicting the thrust force exerted through
drilling process. Different parameter for machining are analysed for thrust force by using
response surface method. RAMULU M et al. 2002 investigated on drilling characteristics
of (Al2O3) p/6061composite pertaining to drill force, tool wear, chip formation, quality of
drilled hole and PCD drills dominates all other drills. DI ZHANG et al. 2008 has
investigates the Aluminum-Silicon Carbide composites, effects the spatial distribution of
reinforcing elements results in the delamination of particle in highly accumulated area
increases. MAHAMANI A. 2014 deals with study of delamination in drilling of aluminum
2219 matrix with TiB2/ZrB2 reinforcement material results in drill diameter, feed rate and
decrease in surface roughness due to spindle speed and point angle. GAITONDE V N et
al. 2008 predicted that the delaminating of medium density fiberboard through drilling by
surface response method and design with Taguchi method. BASAVARAJAPPA et al.
2008 has concluded the drilling characteristics of hybrid composites by taking drilling
parameter into account. Analysis of the drilling characteristics done by using the Taguchi
design of experiments and analysis of variance. The present article physically verifies the
thrust force generated using the outcome of various drilling parameters in machining
Al/SiC-TiO2 Nano composite [ PALANIKUMAR K. AND KARTHIKEYAN R. 2007]. The titanium nitride coated HSS twist drill bit of dia 6 mm, 8 mm, and 10 mm using a
vertical machining center for conduct of experiment. Response surface model for the
above experiment are developed. The research concludes, by increasing the feed rate and
drill diameter the thrust force increases Box-Behnken Design, analysis of variance is
utilized for the cutting parameters optimization.
2. Materials and Methodology
Table 1: Aluminum alloy Composition
Elements Si Fe Cu Mn Mg Zn Cr Ti Al
Weight
(%) 0.638 0.295 0.259 0.097 0.878 0.035 0.092 0.029 Balance
Table 2. Chemical composition of Titanium oxide (TiO2, Rutile) Nano particles
Chemical composition of Aluminum alloy Al6061 has been tabulated as shown in
Table 1, and used as matrix material. The reinforcement materials such as 230 grit size of
SiC, and (20 – 50 nm) of Nano TiO2, are used for experimental fabrication. The
composites were manufactured utilizing stir casting method with 93 wt% of Al, 5 wt% of
the SiC powder and a fixed amount of 2 wt% of TiO2. Al 6061 ingot in round form were
sliced into little pieces and taken in crucible which was heated up to 850oC to get fluid
shape and after that the temperature is step by step diminished till it achieves 620oC where
TiO2 S Si Al Mg
>99.5 <0.045 <0.025 <0.015 <0.005
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it accomplishes a semisolid state. Estimated amount of SiC and TiO2 particles was heated
at 720oC and added consistently with mixed aluminum liquid. The entire prepared
composite was continuously stirred at 750 revolutions per minute for 6 – 8 min and after
that the melt filled steel mould and permitted to cool to acquire 100 x 100 x 10 mm size of
plate. Sample was prepared in the shape of square plate which specification is 100 × 100 ×
10 mm. The TiN coated twist drilling bit of size 6mm, 8mm, and 10mm are used. Drilling
experiments were conducted with support of CNC Vertical Milling Centre (VMC100)
[PALANIKUMAR K et al. 2014]. The drilling sample was produced by using
specification 100 × 100 × 10 mm square block. Coated twist drilling bit of sizes, 6, 8, and
10 mm diameter were used. Dynamometer was connected by cable with three station
charge amplifier. The work piece is clamped on dynamometer which in turn fixed to the
working bench of the vertical milling machine [NOOR UL HAQ.A et al. 2008].
The experiment details are shown in table 3 and drilled Al MMCs are shown in
figure 2. Drilling was performed at 1500, 2000, 2500 (rpm) spindle speeds and 0.05, 0.075
and 0.1 feed rate (rev/min) and hence holes were created on the work piece. Drilling tasks
were performed under dry cutting conditions. Every experiment was conducted by keeping
different drill diameter, with varying feed, and speed, and the values were analyzed
[PAULO DAVIM J.2003.] By using data acquisition system, the data are collected and
recorded. With the application of dynamometer, cutting forces were constantly recorded.
Table 3: Details of Cutting Parameter
Sl.
No representation
Drilling
Parameter
Range/Level
Units 1 2 3
1. d Drill Diameter 6 8 10 mm
2. f Feed Rate 0.05 0.075 0.1 mm/rev
3. N Spindle Speed 1500 2000 2500 rpm
3. Result and Discussion
3.1 Modeling and optimization of drilling parameters using response surface
methodology
The full factorial experiment of seventeen run, with three input parameter each varies with
three input parameter and varies at three levels on Taguchi technique and design process
shown in Table 4. Drilling operation was conducted with aid of computer numerical
control Vertical Milling Centre and Box–Behnken experimental design is employed. The
parameters are chosen according to different literature study. The experiments were
conducted using TiN coated twist drill bit.
Figure 1: Shows the CNC Vertical Milling Centre in which drilling of Al 95% SiC
3% TiO2 2% combination composite of different diameter is performed.
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Thrust force exerted by drilling has been calculated by dynamometer. This
experiment verifies that Box–Behnken design is analytical tool used in the design of
experiments. This design is economical and it is alternative process to the central design
for composite. The three level of experimental value are analyzed.
Table 4: Box-Behnken design consisting of experiments for the study of three
experimental Values for Thrust Force.
Table 5: Result of ANOVA for Quadratic model subjected to Thrust force generated
during drilling of Al-SiC/ Nano TiO2 Composite.
Source Sum of
Squares
df Mean
Square
F-value p-value
Model 7.417E+05 9 82414.85 87.64 < 0.0001 significant
d-Drill
diameter
83836.60 1 83836.60 89.15 < 0.0001
f-Feed 15636.89 1 15636.89 16.63 0.0047
N-Spindle
speed
802.69 1 802.69 0.8536 0.3863
df 46010.25 1 46010.25 48.93 0.0002
dN 256.00 1 256.00 0.2722 0.6179
fN 506.25 1 506.25 0.5384 0.4870
d² 77135.25 1 77135.25 82.03 < 0.0001
f² 1425.52 1 1425.52 1.52 0.2580
N² 7839.67 1 7839.67 8.34 0.0234
Residual 6582.55 7 940.36
Lack of Fit 3031.75 3 1010.58 1.14 0.4345 not significant
Pure Error 3550.80 4 887.70
Cor Total 7.483E+05 16
Factor 1 Factor 2 Factor 3 Response 1
Std Run d: Drill diameter f: Feed C: Spindle speed Thrust Force
mm mm/rev. rpm N
1 2 6 0.05 2000 192
2 16 10 0.05 2000 423
3 11 6 0.1 2000 235
4 12 10 0.1 2000 895
5 14 6 0.075 1500 202
6 10 10 0.075 1500 702
7 7 6 0.075 2500 204
8 4 10 0.075 2500 736
9 15 8 0.05 1500 456
10 1 8 0.1 1500 767
11 8 8 0.05 2500 485
12 17 8 0.1 2500 751
13 3 8 0.075 2000 542
14 13 8 0.075 2000 551
15 9 8 0.075 2000 605
16 5 8 0.075 2000 534
17 6 8 0.075 2000 534
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Table 5. Shows the ANNOVA is employed to determine the thrust force generated
during drilling operation of Al–SiC/ Nano TiO2 Composite. The “P” value is less than
0.05 for the model indicates its acceptability at the confidence level of 95%. It is prudent
since it shows that the model terms have remarkable effect on the response. The effects of
various individual models like d, f and interaction of d and f are significant model terms.
Not significant models are N, d2, f2, N2 interaction of N with d and f respectively. The
significant index has not been evidenced while arriving the value through the analysis of
variance in turn it lead to the “lack of fit” [BASAVARAJAPPA S.2009]. Hence the
proposed model is effective in determining the drilled induced thrust force which was
developed during the drilling of Al-SiC/Nano TiO2 composite. Thrust force is influenced
to greater extent by drill diameter, followed by the feed rate and spindle speed.
3.2 Thrust Force Analysis of Nano Composite.
Figure 2 — Plot for Normal probability (a) Graph for correlation (b) Graph for
thrust force (c) Residuals Vs Run (d) Residuals Vs Predicted
Experimental model shows the conclusion of linear, square and interaction. The quadratic
design model, with experimental data relationship was build up for the thrust generated in
drilling of Al – SiC/ Nano TiO2 Composite. By taking input values of variables` for
composite in account, the model is mentioned below:
Thrust Force. (N) = -871.90000+484.71250d -14316.00000f -0.674650N +2145.00000d *
f +0.008000d * N +0.008000f * N --33.83750d² +29440.00000f ² +0.000173N2
From the figure, the development of model shows normality against externally residual. In
Fig.3 (a). Evident so as to the values obtain from the model are distributed on the line,
have shown that developed model is effective. Fig. 3(b) evident that correlation among
(a) (b)
(c) (d)
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the experimental relations made with that of determined values. The result shows that the
experimental values having close relation with empirical value produced and thus the
developed model been the beneficial prediction of cutting force produce thrust in drilling.
Fig.3 (c) evident that statistics related to residual. Externally studentized residuals
indicates the optimized surface model has been succeeded to forecast a thrust force for
three variables in drilling operation for Al-Si with nano TiO2 composites. Fig.1 (d) evident
that predicted value vs externally studentized residuals. It clearly reveals the extreme
deviation is 4.84963, and is with-in limit.
Table.6: Fit Statistics
Std. Dev. 30.67 R² 0.9912
Mean 518.47 Adjusted R² 0.9799
C.V. % 5.91 Predicted R² 0.9278
Adeq Precision 32.0482
The predicted value of square of R (0.9278) is not as nearer to the value of the square of
adjusted R (0.9799) in turn received the difference is less than 0.2, which is not desirable.
It may show that possible problem may be with a developed model or data or specify a
large block effect. Necessary object to examine are outliers, empirical model reduction etc.
The signal to noise ratio can be measured by Adeq precision. It was observed that, the
ratio was greater than 4, which is desirable. Adequate level of ratio 32.0482 was observed
during the study. Similarly, the navigation on design space can be very easily found out by
this method.
From, the given model drill diameter represents d, feed represents, f and spindle
speed represent, N. The developed model has been examined using the correlation
coefficient, R2. It evident that the residuals lies in straight line mean with the purpose of
the error are generally scattered. Since, the model produces R2 values as 0.9912 and the
adjusted R2 values as 0.9799. Thus, achieved values confirm that model is extremely
reliable. Therefore, proves the model was significant at 95% at probability level.
3.2.1 Drilling Parameter Effect Graph
(a) (b
)
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Fig.3 Drilling Parameter Effect Graph
Fig 2 clearly indicates the effect of process parameter on thrust force during drilling
operation. If feed rate increases during process leads to increase the stress on the drill bit
in the opposite direction of feed (vertical direction) as a result thrust force increased during
drilling. This is also due to increase in contact surface between the drilled portion and
circumference of drill bit which shows a thrust force increase in throughout drilling of
aluminum metal matrix composite. By increasing spindle speed, traverse rate increases
and makes the material soften which leads to reduce the thrust force in the drilling
operation. By continuous increase in spindle speed to 2500 rpm makes the thrust force
increases slightly because of heat generation at the interface of the drill bit and the contact
surface of the hole.
3.2.2 Interaction Graph Thrust Force
(c)
(a) (b)
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Fig.4 Interaction Graph Thrust Force (3D)
The figure 3 clearly shows the 3D interaction graph, which neatly gives the
prediction values of Feed rate, Spindle speed, and Drill diameter. The predicted parameter
gives the outcome of thrust force. It clearly indicates that the thrust force during drilling is
increased by increasing the feed rate, spindle speed and drill diameter. Among these three
parameters, smaller drill diameter gives the lower thrust force which is opted for drilling a
composite with low burr [PALANIKUMAR.K et al. 2015]. 3D interaction graph can be a
reliable tool to evaluate the process parameter from the given level of factors with
minimum deviation.
3.2.3 Response on contour plot:
(a)
2.3
62.
36
(c)
(b)
2.3
62.
36
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Fig.5 Estimated contour plots for thrust force
Figure 6 (a to c) shows the estimated contour plots of thrust force for Al/SiC–TiO2
Nano composites. The contour plots examined gives the value of thrust force desirability
at any region of the drilling parameters in the experimental work. Response surface model
is used to analyze the optimization of process parameters in drilling operation. This model
is derived on desirability function approach and progress by Design Experts Software. By
this approach, a large number of solution has been developed and the best solution is
preferred based on high desirability.
3.2.4 SEM images showing drilled hole surface:
Damage Surface of the drilled sample work piece has been investigated. Testing
of the drilled surface of the hole was executed by scanning electron microscope. Figure 4
shows, that machined surface was properly examined and the micro cracks, wrap, trenches
presence on the drilled surface, are found. The occurrence of microscopic cracks is due to
the strain hardening of the material. Among, the different diameter drill, Al 95% SiC 3%
TiO2 2% combination having feed rate 0.1 mm/rev, with speed 2500 rpm and drill
diameter ø6 mm reveals less occurrence of microscopic cracks. The grooves formed by the
drilling action in the composite specimen get smoother by increase in the temperature
which leads to plastic deformation of the material [BALASIVANANDHAPRABU.S et al.
2006]. Increasing the drill bit diameter from 6mm to 8mm resulted in more surface
smoothness by flattening the extrusions, thus reducing the friction coefficient also. The
asperities of the hard counter surface can be clearly seen with sharpness and corrugated
structures.
(a) (b)
(c)
2.3
62.
36
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(i) Al 95% SiC 3% TiO2 2% combination with ø10 mm
(ii) Al 95% SiC 3% TiO2 2% combination with ø8 mm
(c)
(a) (b)
(c)
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(iii) Al 95% SiC 3% TiO2 2% combination with ø6 mm
Fig: 6. SEM images showing the drilled surface of Al – Si C Metal Matrix with Ti O2
Nano Composite with feed rate 0.1 mm/rev and with speed of 2500 rpm in different
drill diameter such as ø 6, ø 8, ø 10. (i) Entry (ii) Intermediate & (iii) Exit Level
3.3 Quantitative Analysis of Element
Energy dispersive spectroscopic (EDAX) has been analyses to study the composition of
element present in Al – SiC / Nano TiO2 Composite. Fig. 5. Shows EDAX spectra of
Al/SiC - Nano TiO2 Composite [Ramesh S et al. 2008].
(c)
(a) (b)
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Fig.7: The spectrum of EDAX shows he presence of the elements in the
reaction layer interface of Al – SiC TiO2 Nano Composite in Ɵ10 mm drilled surface
feed rate 0.1 mm/rev and with speed of 2500 rpm
Table 7: EDX showing the elements percentage of Al–SiC TiO2 Nano composite Ɵ10
mm drilled surface.
Net Counts
C O Al Si Ti
Base(1780)_pt1 0 662 76175 255 6
Weight %
C O Al Si Ti
Base(1780)_pt1 0.00 3.50 95.70 0.77 0.03
Atom %
C O Al Si Ti
Base(1780)_pt1 0.00 5.77 93.49 0.72 0.02
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Fig.8: The spectrum of EDAX shows he presence of the elements in the reaction layer
interface of Al – SiC TiO2 Nano Composite in Ɵ8mm drilled surface under feed rate
0.1 mm/rev and with speed of 2500 rpm
Table 8: EDX showing the elements percentage of Al–SiC TiO2 Nano composite Ɵ8
mm drilled surface.
Net Counts
C O Al Si Ti
Base(1779)_pt1 13 717 143008 76 44
Weight %
C O Al Si Ti
Base(1779)_pt1 0.28 2.10 97.38 0.13 0.12
Atom %
C O Al Si Ti
Base(1779)_pt1 0.63 3.48 95.71 0.12 0.06
Fig.9: The spectrum of EDAX shows he presence of the elements in the reaction layer
interface of Al – SiC TiO2 Nano Composite in Ɵ6mm drilled area under feed rate 0.1
mm/rev and with speed of 2500 rpm
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Table 9: EDX showing the elements percentage of Al–SiC TiO2 Nano composite Ɵ6
mm drilled surface.
Net Counts
C O Al Si Ti
Base (1778) _pt1 23 627 86187 190 13
Weight %
C O Al Si Ti
Base (1778) _pt1 0.78 2.97 95.68 0.51 0.06
Atom %
C O Al Si Ti
Base (1778) _pt1 1.71 4.86 92.92 0.47 0.03
From Table shows, the composition of elements percentage of Al–SiC TiO2
Nanocomposites. The spectrum of EDAX show evidence of the existence of the elements
aluminium, silicon titanium and carbon in the reaction layer interface shown in Figure. It
has been understood that EDAX detect little amount of oxygen extracted from an oxide
layer produced during sample preparation. It is understood from spectrum of EDX that the
peak of Al is in the order of five times higher than the peak of Si and other small peaks are
the elements Ti and O are revealed.
Table 7, reveals that Weight % of 95.70% Al, 0.77 % Silicon,0.03% titanium, 0.00%
Carbon and 3.50 % Oxide elements and Atom % of 93.49% Al, 0.72 % Silicon,0.02%
titanium, 0.00% Carbon and 5.77 % Oxide elements detected in the Ɵ10 mm drilled
surface of Al 93% SiC 5% TiO2 2% Composite sample.
Table 8, reveals that Weight % of 97.38% Al, 0.13 % Silicon,0.12% titanium, 0.28 %
Carbon and 2.10 % Oxide elements and Atom % of 95.71 % Al, 0.12 % Silicon,0.06 %
titanium, 0.63% Carbon and 3.48 % Oxide elements detected in the Ɵ8 mm drilled surface
of Al 93% SiC 5% TiO2 2% Composite sample.
Table 9, reveals that Weight % of 95.68 % Al, 0.51 % Silicon,0.06 % titanium, 0.78 %
Carbon and 2.97 % Oxide elements and Atom % of 92.92 % Al, 0.47 % Silicon,0.03 %
titanium, 1.17 % Carbon and 4.86 % Oxide elements detected in the in Ɵ6mm drilled
surface of Al 93% SiC 5% TiO2 2% Composite sample.
3.4 Surface Roughness Analysis
Atomic Force Microscope (AFM) analysis is a method to analyse the surface
roughness in its full 3D glory. This type of microscope has a rectangular probe, with a
sharp tip and this probe end captures the hole surface of very high-resolution images, it
also produces the resolution of fractions of nanometer. The gold coated silicon nitride
rectangular shape cantilever type probe measures surface roughness of drilled hole.
The AFM topographical showing (Fig.6(a)) the surface roughness in 3D image
and also shows 2D height for Al-SiC-Nano TiO2 surfaces[RAJMOHAN.T et al. 2013].
(Fig.6(b)) shows the corresponding 3D images and the peak and clustering of structure
accountable for bouncy surface and shows the ‘trench’ which can be identify with as
surface defects.
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Fig. 10 shows the examination on surface of Al – SiC / Nano TiO2 Metal Matrix
composite by Atomic Force Microscope, (a) & (b) Microstructure analysis (c) Line
image of cross-sectional position of the morphology (d) Section Analysis details
In the given sample of composite, the depth of micro cracks are evaluate and
recorded. The graph depicts the micro level cracks depth in Al – SiC / Nano TiO2 Metal
Matrix composites sample range from 0.19481µm to 0.89063µm by considerably
increasing with the pulse current and pulse on duration. Micro cracks developed after
drilling is an acceptable range, which in turn leads to assemble or further more operation
can be done in a drilled hole.
4. Conclusion Present work deals with investigational outcome during the drilling of Al / SiC - TiO2
Nano Composites on different cutting condition pertaining to thrust in drilling using TiN
coated twist drill. The conclusions are mentioned below:
1. Development of Response surface model using Box – Benken Design to correlate
the drill parameter with reference to thrust force. The coefficient of correlation
0.9885 indicates that, the model developed is adequate. This proves that the model
was vital at 95% at probability and so, the models are often well utilized in Al –
SiC/ Nano TiO2 composite drilling.
2. Result of various parameters in drilling operation such as drill dia, feed rate and
spindle speed of Al– SiC/ Nano TiO2 Composite has been study for thrust force
using 3D surface plots.
3. The most vital aspects in influencing the drilling process of Al / SiC - Nano TiO2
composite are feed rate and drill diameter. Feed rate and drill diameter increases,
leads in increasing of thrust force, whereas spindle rotation reduces the thrust
forces and the increases for further increasing the spindle speed.
(a) (b)
(c)
(d)
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4. The thrust force is predicted by generation of experimental model. The
investigation proves that model is best suited to predict the drilling which
stimulate thrust in Al – SiC/ Nano TiO2 composite.
5. The characterization of TiO2 Nano particle in which SiC particles are dispersed in
aluminum are studied using SEM and EDAX analysis. The results conclude the
existence of SiC and TiO2 Nano particle in the Al matrix composites. It also shows
that drilled surface was properly examined and the micro cracks, wrap, trenches
presence on the drilled surface, are found. The formation of microscopic cracks,
because of existence of hard SiC set on their path. Once a cluster of microscopic
cracks meet each other close to a particle, void around, set on is developed. The
spectrum of EDAX show evidence of the existence of the elements aluminum,
titanium, silicon and carbon in the reaction layer interface.
6. AFM topographic image shows the Surface profiles that are taken at three
different locations of the drilled hole. With three-dimension image, the normal
grain width and height and also extreme grain width and height are measured.
More quantity of group of micro grains, le ads to measure the larger values of
width and height of the micro cracks.
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Tierärztliche Praxis
ISSN: 0303-6286
Vol 39, Issue 11, November - 2019
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