On the Machinability of an Al-63%SiC Metal Matrix Composite

Abstract

This paper presents a preliminary study of aluminium matrix composite materials during machining, with a special focus on their behavior under conventional processes. This work will expand the knowledge of these materials, which is considered to be strategic for some industrial sectors, such as the aeronautics, electronics, and automotive sectors. Finding a machining model will allow us to define the necessary parameters when applying the materials to industry. As a previous step of the material and its machining, an experimental state-of-the-art review has been carried out, revealing a lack of studies about the composition and material properties, processes, tools, and recommended parameters. The results obtained and reflected in this paper are as follows; SiC is present in metallic matrix composite (MMC) materials in a very wide variety of sizes. A metallographic study of the material confirms the high percentage of reinforcement and very high microhardness values registered. During the machining process, tools present a very high level of wear in a very short amount of time, where chips are generated and arcs are segmented, revealing the high microhardness of the material, which is given by its high concentration of SiC. The chip shape is the same among other materials with a similar microhardness, such as Ti or its alloys. The forces registered in the machining process are quite different from conventional alloys and are more similar to the values of harder alloys, which is also the case for chip generation. The results coincide, in part, with previous studies and also give new insight into the behavior of this material, which does not conform to the assumptions for standard metallic materials, where the hypothesis of Shaffer is not directly applicable. On the other hand, here, cutting forces do not behave in accordance with the traditional model. This paper will contribute to improve the knowledge of the Al-63%SiC MMC itself and the machining behavior.