A Numerical Simulation of Machining 6061 Syntactic Foams Reinforced with Hollow Al2O3 Shells
Abstract
:1. Introduction
2. Materials and Methods
2.1. Numerical Model of the Machining of Aluminum Closed Cell Syntactic Foams
2.2. Material Model
2.3. Chip Separation Criterion
2.4. Chip–Tool Interaction
2.5. Experimental Validation
3. Results and Discussion
3.1. Machining Forces and Temperature Distribution
3.2. Effect of the Process Parameters on the Simulated Machining-Induced Stress
4. Conclusions
- An increase in the cutting speed resulted in a reduction of the cutting forces by at least 33%, primarily due to thermal softening of the matrix as indicated by the temperature distribution contours. Therefore, the magnitude of machining-induced tensile stresses on the cutting layer increased by 20%.
- Machining at higher uncut chip thickness resulted in an increase of the machining force by almost 140%, leading to an increase in machining-induced stress values by 35%.
- The higher the volume fraction of hollow alumina shells and the finer the shell diameter, the higher the magnitude of the cutting forces. A higher machining-induced stress depth was recorded for syntactic foams with coarser alumina shells.
- A favorable compressive stress distribution in the machined layer was obtained while machining at lower cutting speed and uncut chip thickness values for a volume fraction of 10% hollow alumina shell reinforcements.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Chemical Composition of 6061 Aluminum in Weight (%) | |||||||
Al | Cr | Cu | Fe | Si | Mg | Mn | Zn |
95.8–98.6 | 0.04–0.35 | 0.15–0.4 | 0.7 | 0.4 | 1.5 | 0.1 | 0.25 |
Chemical Composition of the Hollow Alumina Shell in Weight (%) | |||||||
Al2O3 | Fe2O3 | CaO | SiO2 | Na2O | |||
99.7 | 0.003 | 0.01 | 0.025 | 0.26 |
Hollow Alumina Shell | |||||
Physical Properties | |||||
Bulk Density (g/cm3) | Average Porosity (%) | Average Wall Thickness (μm) | Average Bubble Size (mm) | Bubble vol% | Thermal Conductivity (W m−1K−1) |
1.8 | 83 | 0.04–0.08 | 0.3–0.6 | 10%, 20% | 1.5 |
Mechanical Properties | |||||
Crush Strength (MPa) | Poisson’s Ratio | ||||
10 | 0.231 | ||||
6061 Matrix | |||||
Physical Properties | |||||
Density (g/cm3) | Thermal Conductivity (W m−1K−1) | Specific Heat (J kg−1K−1) | |||
2.7 | 165 | 896 | |||
Mechanical Properties | |||||
Poisson Ratio | Compressive Strength (MPa) | Yield Strength (MPa) | Young’s Modulus (GPa) | ||
0.33 | 250 | 150 | 68 |
Thermal Conductivity (W m−1K−1) | Coefficient of Thermal Expansion (1/K) | Young’s Modulus (GPa) | Poisson’s Ratio | Density (g/cm3) | Specific Heat (J kg−1K−1) |
---|---|---|---|---|---|
110 | 5.5 × 10−6 | 700 | 0.31 | 15.6 | 39.8 |
Matrix | 6061 aluminum |
Reinforcement | Hollow alumina thin-walled shell |
Tool | Carbide-coated insert from SandvikTM |
Rake angle and clearance angle | 6° and 7° |
Cutting speed (m/min) | 25, 50, 100 |
Undeformed Chip Thickness (mm) | 0.02, 0.07, 0.15, 0.2 |
Volume fraction of hollow microsphere | 10%, 20% |
Average size of hollow microsphere (mm) | 0.1–0.5 mm, 0.5–1 mm |
Width of cut (mm) | 3 |
Lubrication | Dry |
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Thomas, K.; Kannan, S.; Nazzal, M.; Pervaiz, S.; Karthikeyan, R. A Numerical Simulation of Machining 6061 Syntactic Foams Reinforced with Hollow Al2O3 Shells. Metals 2022, 12, 596. https://doi.org/10.3390/met12040596
Thomas K, Kannan S, Nazzal M, Pervaiz S, Karthikeyan R. A Numerical Simulation of Machining 6061 Syntactic Foams Reinforced with Hollow Al2O3 Shells. Metals. 2022; 12(4):596. https://doi.org/10.3390/met12040596
Chicago/Turabian StyleThomas, Kevin, Sathish Kannan, Mohammad Nazzal, Salman Pervaiz, and Ramanujam Karthikeyan. 2022. "A Numerical Simulation of Machining 6061 Syntactic Foams Reinforced with Hollow Al2O3 Shells" Metals 12, no. 4: 596. https://doi.org/10.3390/met12040596