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Machining of Hard-to-Cut Materials: Impact of Varying Weight Proportion of Boron Carbide Particle Addition on Cutting Force and Surface Roughness of Al6061

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Abstract

The current work mainly focused on evaluating the impact of machinability parameters on the roughness of the surface and components of the cutting force. The tests were carried out on the base alloy (Al6061) and composite (Al6061-B4C) reinforced with different weight percentages (5-9 wt.%) of boron carbide particles (37 µm). The ready specimen was assigned to turning process by using a traditional lathe machine with the assistance of polycrystalline diamond (PCD) tool to examine the impact of varying the weight percentage of boron carbide addition on surface roughness and cutting forces. Obtained outcomes show that the components of cutting force reduce with increment in the weight percentage of boron carbide particle strengthening, which can be related primarily to increased porosity, stiffness and density dislocations. Electron microscopy picture produced from a composite with a small weight percentage (5 wt.%) of boron carbide particulates, which is machined at a superior cutting speed and a superior depth of cut, evidently confirms the existence of built-up edge at the edge of the PCD tool. In addition, cutting forces advance with increment in the depth of cut and feed rate for Al6061 alloy matrix and Al6061 strengthened with boron carbide composites. It is identified that the quality of the surface is drastically enhanced by improving cutting speed and decreasing depth of cut and feed rate. Further, influence of 8, 37 and 88 micron B4C particle size and reinforcement wt.% on relative machinability index was studied.

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Authors and Affiliations

  1. TATA Advanced Materials Limited, Bangalore, Karnataka, India

    Vijaykumar Hiremath

  2. Department of Mechanical Engineering, R&D Centre, Siddaganga Institute of Technology, VTU, Tumakuru, Karnataka, 572103, India

    V. Bharath & V. Auradi

  3. Department of Industrial and Production Engineering, Basaveshwar Engineering College, VTU, Bagalkot, Karnataka, 587 102, India

    S. T. Dundur

  4. Aircraft Research and Design Centre, HAL, Bangalore, Karnataka, India

    Madeva Nagaral

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Hiremath, V., Bharath, V., Auradi, V. et al. Machining of Hard-to-Cut Materials: Impact of Varying Weight Proportion of Boron Carbide Particle Addition on Cutting Force and Surface Roughness of Al6061. J. of Materi Eng and Perform 31, 3784–3791 (2022). https://doi.org/10.1007/s11665-021-06480-y

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