Seminar-II report

0n
“ Drilling of Ceramic Reinforced Metal
Matrix Composite- a Review”
BY
Anand S. Kakde

Guided by
Prof. N. G. Patil
Drilling
 Drilling is an operation of
making hole by removing a
volume of metal from the job by
a rotating cutting tool called
drill.
 A drill is a rotary end-cutting
tool with one or more cutting
lips and usually one or more
flutes for the passage of chips
and the admission of cutting
fluids.
 Most important conventional
mechanical process.
 It accounts for major portion of
overall machining process.
Composite Materials
Classification as suggested by Karl U. Kainer [7]
 LITERATURE REVIEW
Karl U. Kainer [7] mentioned that the reinforcement of metals can have many different
objectives1.
1. Increase in yield strength and tensile strength at room temperature and above
2. Increase in creep resistance at higher temperatures compared to that of conventional
alloys.
3. Increase in fatigue strength, especially at higher temperatures.
4. Improvement of thermal shock resistance.
5. Improvement of corrosion resistance.
6. Increase in Young’s modulus.
7. Reduction of thermal elongation.
8. Increase in strength of conducting materials while maintaining the high
conductivity,
9. Improvement in low temperature creep resistance.
10. Improvement of burnout behavior.
11. Improvement of wear behavior.
12. Increase in operating time of spot welding electrodes by reduction of burn outs,
13. Production of layer composite materials for electronic components,
14. Production of ductile composite superconductors,
15. Production of magnetic materials with special properties.
LITERATURE REVIEW
Types of reinforcements
Types (Karl U. Kainer [7])
1. Dispersion hardened and
particle composites
2. Layer composites
(laminates)
3. Fiber composites
4. Infiltration composites
 Figure shows SiC particles
which are commonly
incorporated in aluminum this
reinforcement of metal matrix
materials is reported by N
Chawla and KK Chawla
 Limitations in Drilling MMCs
 Hybrid MMC consist of at least three constituents- a metal or an
alloy matrix and two reinforcements in various forms, bonded
together at the atomic level in the composite3.(H. Hochenga,∗, C.C. Tsao )
 Despite their higher specific properties of strength and stiffness,
the nonhomogeneous and anisotropic nature combined with the
abrasive reinforcements render their machining difficult 3.
 Drilling of SiCp/Al MMC results in excessive surface damage
and tool wear due to the abrasive nature of the ceramic particales2.
(A Riaz Ahmed)
 Drilling-induces damages, such as delamination of tool, burrs,
swelling and fiber pullout is the characteristic in machining
composite4 .(Rajmohan & Oalani Kumar)
LITERATURE REVIEW
Surface Quality in drilling composites

Alakesh Manna* Kanwaljeet Singh in their paper mentioned the

following:
1. Reliability of the machined component is largely dependent on
surface quality, especially for high- strength applications.
2. In machining the term quality is based on two main aspects;
surface topography (surface roughness); machining damage
(delamination)
3. Formation of surface geometry is function of tool geometry,
kinematic effects of the tool relative to the work, machine tool
rigidity and chip formation mechanisms.
4. Unlike metals, the micro geometry of machined MMC is less
regular and it is usually rougher as the material is more
inhomogeneous.
 LITERATURE REVIEW
Surface Quality in drilling composites (Carbide tip drill)

 Figure-2.4 shows the effects of the

spindle speed (rev/min) and feed
rate (mm/rev) on the surface
roughness height, Ra(Alakesh
Manna* Kanwaljeet )
Observations are
 the Ra value increases with
increase of feed rate.
 during drilling it was observed
that initially there is an increment
of Ra value, then decreases and
finally increases with increase of
spindle speed.
 LITERATURE REVIEW
Surface Quality in drilling composites (Pure Carbide drill)

 Alakesh Manna* Kanwaljeet in

their paper
 AN INVESTIGATION ON
DRILLED HOLE SURFACE
DURING DRILLING OF
AL/SIC-MMC also found that as
shown in figure, that the value of
surface roughness height, Ra,
increases with increase of feed
rate.
 LITERATURE REVIEW
Surface Quality in drilling composites (Nitride coated drill)

 Alakesh Manna* Kanwaljeet

in cace of Nitride coated drill
found that the value of
surface roughness slightly
increases with increase of
feed rate.
 LITERATURE REVIEW
Surface Quality in drilling composites (Co-Ti coated drill)

 Figure shows the 3-D

surface of the influence of
feed rate on the surface
roughness at different
spindle speeds using Co-Ti
coated drill. From the figure,
it is clear that the value of
surface roughness increases
with increase of feed rate.
LITERATURE REVIEW
Surface Quality in drilling composites (HSS drill)

 Figure shows the 3-D surface

of the influence of feed rate on
the surface roughness at
different spindle speed using
HSS drill. From the figure , it is
clear that the value of surface
roughness slightly increases
with increase of feed rate.
 In general drilling of Al/SiC-
MMC hole surface quality
decreases with increase of
spindle speed for the following
drills high speed steel, carbide
tipped, cobalt-titanium coated
and nitride coated drills.
(Alakesh Manna* Kanwaljeet )
LITERATURE REVIEW
VARIOUS PARAMETERS AFFECTING THE PERFORMANCE
 A. Feed rate
 S.Senthil babu, Dr.B K.Vinayagam,9 had reported that as the feed rate increased,
the cutting temperature also increased and this may cause weakening of the
binding between the matrix and the SiCp,
 Paulo Davim & Conceicao Antonio10 had suggested that at a constant cutting
speed, the surface finish of the holes of the drilled samples deteriorates with
increasing feed rate.
 S.Senthil babu, Dr.B K.Vinayagam,9 had suggested that feed rate affects drilling
forces and wear, also the surface roughness decrease with increasing feed rate at
each spindle-speed.
 Ramulu11 had reported that feed rate is the main factor, which is influencing the
thrust force, also the lowest surface roughness parameters occurred at the lowest
feed rate.
 S.Senthil babu, Dr.B K.Vinayagam,9 also reported that the surface roughness
value increases with increase in feed rate and decreases with increase in cutting
speed.
 S.Senthil babu, Dr.B K.Vinayagam,9 studed that the various cutting parameters
and selection of cutting tools for drilling of Al based MMCs and reported that the
low feed rates produced rapid flank wear on the tool, and also mentioned that the
tool wear increase with feed rate at a constant cutting speed
 LITERATURE REVIEW
VARIOUS PARAMETERS AFFECTING THE PERFORMANCE
 A. Feed rate
 Figure shows Surface
roughness as a function of
feed rate under different
cutting speeds reported by
Ramulu et al.11
LITERATURE REVIEW
VARIOUS PARAMETERS AFFECTING THE PERFORMANCE

 A. Feed rate
 S.Senthil babu, Dr.B K.Vinayagam,9
studed that the various cutting
parameters and selection of cutting
tools for drilling of Al based MMCs
and reported that the low feed rates
produced rapid flank wear on the
tool, and also mentioned that the
tool wear increase with feed rate at
a constant cutting speed.
 Tool wear further increased by
increasing the percentage of Sicp as
shown in Figure.
 Fig.shows Tool wear as a function
of feed rate at constant cutting
speed reported by S.Senthil babu,
Dr.B K.Vinayagam
LITERATURE REVIEW
VARIOUS PARAMETERS AFFECTING THE PERFORMANCE

B. Drilling tool and its geometry

 Alakesh Manna* Kanwaljeet Singh8 was reported that as the point angles of
HSS and TiN coated drills increase, the damage zone increased.
However, with increasing point angles of solid carbide drills, the damage
zone decreased
 Fig. below shows Effect of point angles of various drills on the
surface roughness reported by Alakesh Manna8 Kanwaljeet Singh8
LITERATURE REVIEW
VARIOUS PARAMETERS AFFECTING THE PERFORMANCE

B. Drilling tool and its geometry

 Ramulu et al.11 suggested that drilling forces were

significantly influenced by tool materials. HSS drills are
unsuitable for drilling MMCs because of very high tool wear,
poor drilled-hole quality, and higher drilling forces induced.
 S.Senthil babu, Dr.B K.Vinayagam, 9 reported that burr
formation is less when multifaceted carbide drill is used when
compared to conventional coated carbide drills.
 Conventional coated carbide drilling is preferred in
applications that require a good surface finish, and reported
that HSS is not a suitable tool material. PCD tipped drilling
tools were effective over a wide range of operating
conditions.
 LITERATURE REVIEW
VARIOUS PARAMETERS AFFECTING THE PERFORMANCE

C. Cutting speed
1. Ramulu et al. 11 had evaluated the drilling
characteristics in terms of drilling forces,
tool wear, surface finish etc. and reported
that the lowest surface roughness parameters
occurred at the lowest feed rate with highest
cutting speed.
2. S.Senthil babu, Dr.B K.Vinayagam,9 had
analyzed the drilling characteristics and
suggested that the surfaced finish increases
with increase in speed, or the surface
roughness decreases with increase in spindle
speed as shown in Fig.
3. S.Senthil babu, Dr.B K.Vinayagam,9 also
investigated the influence of various cutting
parameters on the drilling performance of Al
based metal matrix composites and
suggested that the surface roughness value
LITERATURE REVIEW
VARIOUS PARAMETERS AFFECTING THE PERFORMANCE

D. Thrust Force
 A Riaz Ahmed, Paravasu Ashokan, Sivanadanam , MK Prakash 3
reported that when drilling of SiCp/Al composites with high
volume fraction and large size of particles, the thrust force vary
linearly with feed rate, while the cutting speed has no significant
effect on the thrust force.
 the PCD drills were subjected to an extremely rapid flank wear, and
the primary wear mechanism includes abrasive wear and the
adhesive wear of the flank face.
 as the size of the SiC particles is very large, the attrition wear can
also take place in drilling these composites.
LITERATURE REVIEW
VARIOUS PARAMETERS AFFECTING THE PERFORMANCE

D. Thrust Force
 S. Madhavan1, S. Balasivanadha
Prabu observed that thrust force is
high as feed rate increases due to the
change in the shear area.
 There is tremendous increase in
thrust force values for PCD because
the amount of margin left after
providing the flute is more. flute is
more. This reveals that drill
geometry has significant effect on
the thrust force.
 The thrust force generally increases
as the speed increases but decreases
further in the case of Carbide and
PCD tool.
FINITE ELEMENT METHOD IN DRILLING
COMPOSITES
 The direct experimental approach to study machining processes is
expensive and time consuming, especially when a wide range of
parameters is included: tool geometry, materials, cutting conditions, etc.
 The alternative approaches are mathematical simulations where numerical
methods are applied.
 To study machining is a quite complicated task where complex disciplines
such as metallurgy, elasticity, plasticity, heat transfer, contact problems,
fracture mechanics, and lubrication are involved.
 The goal of finite-element analysis is to derive a computational model
predicting the deformations, stresses and strains in the workpiece, as well
as the loads on the tool working under specific cutting parameters.
 Physical understanding of microcutting is necessary for developing and
improving the process of ultraprecision metal cutting technology.
 FEMs have also been used to simulate nanoscale cutting.
 FEM can be used to clarify the chip removal of nanoscale cutting and to
reexamine the cutting process in general.
 FINITE ELEMENT METHOD IN DRILLING
COMPOSITES
N. Chawla, K.K. Chawla14 concluded following points in their paper Microstructure based
Finite Element Modelling of particle reinforced MMC.
1. Analytical models are limited in predicting the properties of particle reinforced
MMCs because they do not account for the micro structural factors that influence the
mechanical behavior of the material.
2. 2D microstructure based FEM modeling can capture the anisotropy in deformation
behavior induced by anisotropy in particle orientation. The experimental dependence
of Young’s modulus and tensile strength is confirmed by the 2D microstructure-based
numerical model. Because of the 2D stress state, a realistic comparison to actual
experimental values is not possible.
3. A serial sectioning process can be used to reproduce and visualize the 3D
microstructure of particle reinforced metal matrix composites. The 3D microstructure
accurately represents the alignment, aspect ratio, and distribution of the particles.
4. FEM simulation of the uniaxial loading behavior of particle reinforced MMCs can be
conducted on 3D microstructure obtained from serial sectioning. When compared to
3D unit cell particles (spherical and rectangular prism) and multiparticle models of
simple shape (spherical or ellipsoidal), the 3D microstructure-based models are more
accurate in predicting the local and macroscopic uniaxial deformation behavior of the
composite.
PROBABLE GAPS/AREA TO WORK
FERTHER

Advancement in the materials topology is developing day

by day as per the requirements of the designers and
demand in properties of the materials following was
found.
1. Optimization or economic enhancement of drilling of
MMC.
2. Quality parameters like surface roughness of the
drilled MMC changes as per the variation in volume
percentage of reinforcing materials, which further
developes the need of particularly designed drill bits.
3. FEM can be used to enhance economy of designing a
drill bit as well drilling process as per the particular
configuration of the MMC
CONCLUSIONS

 Drillingprocesses generally carried out at the last of the

manufacturing process.
 In case of MMC being costly the cost of wastage
becomes very high as it includes material cost as well as
process cost.
 MMCs are extremely hard and abrasive in nature and
can not machined by other then PCD drills.
 Their abrasive nature leads to unsatisfactory quality
parameters of machined surface.
 PCD drills also faces high flank wear while operating on
MMCs
 List of references
1. Drilling of SiCp/Al Metal Matrix Composites with Polycrystalline Diamond (PCD) Tools by S. T.
Huang, L. Zhou, J. Chen, and L. F. Xu, Materials and Manufacturing Processes, Aug 2011.

2. Drilling of hybrid Al-5% SiCp-5% metal matrix composites, by A Riaz Ahmed, Paravasu Ashokan,
Sivanadanam , MK Prakash, Springer- Verlag Londan Ltd., 2009.

3. The path towards delamination-free drilling of composite materials, by H. Hochenga, ∗, C.C. Tsao
b, Journal of Materials Processing Technology 167 (2005)

4. ANN model to predict surface roughness in Drilling Hybrid Composites by Rajmohan & Oalani
Kumar, Advance in Production Engineering and Management June 2011

5. Drilling of hybrid AL-5%SiC-5%B4Cp metal metrix composites by A.Riaz Ahmed-Paravasu

Asokan, Springer Verlag London Ltd, Nov 2009,

6. Metal Matrix Composites. Custom-made Materials for Automotive and Aerospace

Engineering.Edited by Karl U. Kainer. 2006 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim
ISBN: 3-527-31360-5

7. AN EXPERIMENTAL INVESTIGATION ON DRILLED HOLE SURFACE DURING DRILLING

OF AL/SIC-MMC, Alakesh Manna* Kanwaljeet Singh, Surface Engineering and Materials
Technology, Vol.1 No.1 July-Dec.2011
 List of references
9 Parameters involved in drilling of Al based Metal Matrix Composites, S.Senthil babu, Dr.B

K.Vinayagam, International Journal of Engineering and Innovative Technology (IJEIT) Volume 1,

Issue 4, April 2012

10 J.Paulo Davim, C.A.Conceicao Antonio, “Optimal drilling of particulate metal matrix composites

based on experimental and numerical procedures” in International journal of Machine tools and

manufacture 41(2001) 21-31.

11 M.Ramulu, P.N.Rao, H.Kao, “Drilling of (Al2O3)p/6061 metal matrix composites” in Journal of

Material processing technology 124 (2002).

12 Experimental investigation and Analysis of Thrust Force in Drilling of Carbon Fibre Reinforced

Plastic Composites using Response Surface Methodology, S. Madhavan1, S. Balasivanadha

Prabu2 1, 2 Department of Mechanical Engineering, College of Engineering Guindy, Anna

University, Chennai-600025, India

13 Finite-element analysis and simulation of machining: a bibliography (1976–1996), Jaroslav

Mackerle, Linko¨ping Institute of Technology, Department of Mechanical Engineering, S-581 83

Linko¨ping, Sweden, Received 26 June 1997

 List of references

14 MICROSTRUCTURE-BASED FINITE ELEMENT MODELING OF PARTICLE

REINFORCED METAL MATRIX COMPOSITES, N. Chawla*, K.K. Chawla** School of

Materials, Arizona State University, Tempe, AZ 85287 USA, Department of Materials Science

and Engineering, University of Alabama at Birmingham, Birmingham, AL 35209 USA

15 Hallquist, lO., (2011), "LS-DYNA3D Theoretical manual," Livermore Software Technology

Corporation.
THANK YOU