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Ultrasonic Assisted Machining of Metal Matrix Composites

Fakoor, Hamed | 2014

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  1. Type of Document: M.Sc. Thesis
  2. Language: Farsi
  3. Document No: 46877 (08)
  4. University: Sharif University of Technology
  5. Department: Mechanical Engineering
  6. Advisor(s): Movahhedy, Mohammad Reza; Akbari, Javad
  7. Abstract:
  8. In metal matrix composites, the metal is reinforced with ceramic particles to get appropriate properties for hardness, resistance to fatigue, wear resistance and strength. Aluminum matrix composites have lower density than steels. These kinds of materials are used in military, automotive and aerospace industries due to their high strength to weight ratio and resistance to corrosion and wear. Application development of these materials are limited due to high machining and production costs. High ductility and strength of these materials and also hardness of ceramic particles cause rapid wear of tools and higher roughness of the surface. In this project the effect of ultrasonic vibration of a cutting tool on the MMC machining forces has been investigated. A system vibrating the cutting tool at the range of 30 thousands Hertz is designed and manufactured. Orthogonal cutting tests were performed on Al1100- Al2O3 (7.5%wt), Al7075- Al2O3 (5%wt) and Cu-Al2O3 (1%wt) metal matrix composites with the particle size of 10μm, 30μ and 10nm. 3D FEM of CT Al7075-Al2O3 is simulated and 2D FEM of Cu-Al2O3 material is modeled. Then the results are compared to the test results to verify the modeling and simulation. The results show that machining forces and also the tool wear is reduced by applying ultrasonic vibrations. Tool ultrasonic vibrations have more effect on reducing forces in low cutting speeds and high feed rate conditions. The roughness of machined surface goes up at increasing cutting speed conditions and it goes down 27 percent at the cutting speed of 0.5 m/s and 5 percent at the cutting speed of 1 m/s by applying ultrasonic vibrations
  9. Keywords:
  10. Turning ; Metal Matrix Composite (MMC) ; Finite Element Method ; Ultrasonic-Vibration

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