IJRMET Vol. 6, IssuE 2, May - ocT 2016

w w w . i j r m e t . c o m InternatIonal Journal of research In MechanIcal engIneerIng & technology 105

Issn : 2249-5762 (online) | Issn : 2249-5770 (Print)

Experimental Investigation of Material Removal Rate (MRR) on Ultrasonic Machining of Al/SiC

Metal Matrix Composites1Gyanendra Singh, 2Dheeraj Sagar, 3Sunil Kumar Yadav

1,2,3Dept. of Mechanical Engineering, Invertis University, Bareilly, UP, India

AbstractIn a composite material, when the matrix is a metal or an alloy, we have a “Metal Matrix Composite (MMC). Aluminium is used widely as a structural material especially in the aerospace industry because of its light weight properties. Its low strength and low melting point of aluminium were always a problem. An effective method of solving these problems is to use a reinforced element such as SiC particles and whiskers. The main objective of using silicon carbide reinforced aluminium alloy composite system for advanced structural components to replace the existing super alloys. Aluminium alloys are alloys in which aluminium (Al) is the predominant metal. The typical alloying elements are copper, magnesium, manganese, silicon, and zinc. Al/SiC composites have many applications, especially to realize moving parts of vehicles such as pistons, bearings, or brake rotors. The paper presents the material removal rate (MRR) of plates used as work piece made by stir casting in which aluminium (Al) is used as matrix and the silicon carbide (SiC) is used as reinforcement. In this paper three sample of work piece is taken which consist reinforcement as 10%w/w, 15%w/w and 20%w/w.

KeywordsUltrasonic Machining (USM), Grit Size, Power, Material Removal Rate (MRR)

I. IntroductionThe division of manufacturing processes can be done in two groups which are primary manufacturing processes and secondary manufacturing processes. The former provides the basic shape and size to the material as per designer’s requirement. Forming, Casting, powder metallurgy are such processes to name a few. Secondary manufacturing processes are the process which provide the final shape and size with tighter control on dimension, surface characteristics etc. Material removal processes are mostly the secondary manufacturing processes. This process again divided in to conventional and non-traditional process. Ultrasonic machining (USM) is a non-traditional machining process. It is used for machining of hard and brittle material because this material is not machined by conventional process. The principle of USM is based on an electrical current – at a given frequency that fits within the field of ultrasounds –converted from electrical into a mechanical vibration that is transferred to a machining tool. The vibration frequency of the tool is corresponds to the frequency of the electrical signal. These processes don’t use cutting tools and do not create residual stresses in the work piece. In this the removal of hard and brittle materials such as (ceramics, quartz, precious stones, and graphite.) is done by using an axially oscillating tool at ultrasonic frequencies (18–20) kHz takes place. During the oscillation, the abrasive slurry of B4C or SiC is continuously fed into the machining zone between a soft tool (steel or brass) and the work piece. The abrasive particles are, therefore, hammered into the work piece surfaces that causes chipping of fine particles from it. The oscillating tool, vibrates at amplitudes ranging from

10 to 40 µm, which imposes a static pressure on the abrasive grains and feeds down as the material is removed to form the required tool shape. In this tools are made up of tough, strong and ductile materials like stainless steel, steel and other ductile metallic alloys.

Fig. 1: Machine used for Ultrasonic Machining

II. Material and MethodsMMC technologies are divided primarily into two main parts: the primary and the secondary. The primary processing is the composite fabrication by combining ingredient materials (powdered metal and loose ceramic particles, or molten metal and fibre performs), but not necessarily to final shape or final microstructure. The secondary processing instead is the step which obviously follows primary processing, and its aim is to alter the shape or microstructure of the material (shape casting, extrusion, forging, heat-treatment, machining). Secondary processing may change the constituents (phase, shape) of the composite. In this process, the matrix material is heated to above its liquids temperature so that the metal is totally melted. The melt is then cooled down to a temperature between the liquids and solidus points and kept in a semi-solid state. At this stage, the preheated particles are added and mixed. The slurry is again heated to a fully liquid state and mixed thoroughly. This two-step mixing process has been used in the fabrication of aluminium. Among all the well-established metal matrix composite fabrication methods, stir casting is the most economical. For that reason, stir casting is currently the most popular commercial method of producing aluminium based composites. The material fabrication method figure is shown below

IJRMET Vol. 6, IssuE 2, May - ocT 2016 Issn : 2249-5762 (online) | Issn : 2249-5770 (Print)

w w w . i j r m e t . c o m 106 InternatIonal Journal of research In MechanIcal engIneerIng & technology

Fig. 2: Heating of Mixed Powder

Fig. 3: Making of Die

Fig. 4: Al/SiC Plates Made by Stir Casting

III. Experimental WorkIn this experiment the powder of Aluminium (Al) and Silicon (SiC) carbide is used in which Al is used as matrix material and SiC is used as reinforcement material and by using abrasive slurry SiC 200 mesh to optimize the process and parameter of Ultrasonic Machining (USM).

Fig. 5: USM Used for Testing

A. Material Removal Rate (MRR)It is expressed as penetration rate in mm/min for a given cross-section of the tool, or expressed as volume material removal rate in mm3/min after the machining of the work specimens by using different experimental condition as mentioned above, these are the following results obtained.

B. MRR Obtained After the Machining of Work Piece that Contains Sic 10%w/w.Weight of Tool before process = 54.80gms Weight of work material before process = 80.15gms

Table 1: Experimental Value of MRR of Work Piece that Contains SiC 10%w/w at Different VoltageMachining of work piece during process by SiC 220 mesh as abrasive particle slurry.Concentration 9:1Voltage 30 50 70Tool weight, Tw (gm) 54.72 54.70 54.62

Material weight Mw(gm) 80.03 80.01 79.88Operation Time, T (min.) 20 20 20Material Removal Rate (MRR) 0.55 1.76 0.98

Fig. 6: Variation of MRR of Work Piece Containing SiC 10%w/w

In the fig. 6 it is clearly seen that the Material removal rate (MRR) is increasing from 0.55 to 1.76 from 30 to 50 volt and after this it decreases to 0.98 at 70 volt.

C. MRR Obtained After the Machining of Work Piece that Contains Sic 15%w/w.Table 2: Experimental value of MRR of SiC 15%w/w at Different VoltageMachining of work piece during process by SiC 220 mesh as abrasive particle slurry.Concentration 8.5:1.5Voltage 30 50 70Tool weight, Tw (gm) 54.62 54.54 53.52Material weight Mw(gm) 80.05 80.03 79.96Operation Time, T (min.) 20 20 20Material Removal Rate (MRR) 0.50 1.26 0.85

Fig. 7: Variation of MRR of work piece Containing SiC 15%w/w at different voltage

IJRMET Vol. 6, IssuE 2, May - ocT 2016

w w w . i j r m e t . c o m InternatIonal Journal of research In MechanIcal engIneerIng & technology 107

Issn : 2249-5762 (online) | Issn : 2249-5770 (Print)

In the fig. 7 it is clearly seen that the Material removal rate (MRR) is increasing from 0.50 to 1.26 from 30 to 50 volt and after this it decreases to 0.85 at 70 volt.

D. MRR Obtained After the Machining of Work Piece that Contains Sic 10%w/w.Table 3: Experimental value of MRR of work piece that contains SiC 20%w/w.Machining of work piece during process by SiC 220 mesh as abrasive particle slurry.Concentration 8:2Voltage 30 50 70Tool weight, Tw (gm) 54.40 54.20 53.82Material weight Mw(gm) 80.05 80.03 79.96Operation Time, T (min.) 20 20 20Material Removal Rate (MRR) 0.45 1.26 0.84

Fig. 8: Variation of MRR of Work Piece Containing SiC 20%w/w at Different Voltage

In the fig. 8 it is clearly seen that the Material Removal Rate (MRR) is increasing from 0.45 to 1.26 from 30 to 50 volt and after this it decreases to 0.84 at 70 volt.

IV. ConclusionThe variation of MRR (Material removal rate) with power by using concentration 9:1 , 8.5:1.5 and 8:2 shown in fig. 6 to fig. 8. The MRR first increases from the 30V to 50V then decrease from 50v to 70V. In this MRR increase with increase in voltage.The MRR will increase with increase in grain size, but the test result indicates that it decreases when the grain size is too large. So there is a limit to the effect of grain size on the rate, as a very coarse powder cause a reduction in MRRThe higher MRR should be obtained if abrasive material should be hardener than the work piece and typically, larger abrasive grit size and higher slurry concentrations.

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Gyanendra Singh Asst. Professor Mechanical Engineering Department, Invertis University Bareilly (U.P) INDIA.

Dheeraj Sagar Asst. Professor Mechanical Engineering Department, Invertis University Bareilly (U.P) INDIA.

Sunil Yadav M.tech Student Mechanical Engineering Department, Invertis University Bareilly (U.P) INDIA.