IRJET- Synthesis and Comparative Machining Characterization of A356 - Graphite, A356 – Sic and A356 – Casio3 Composites

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 05 Issue: 08 | Aug 2018 www.irjet.net p-ISSN: 2395-0072
© 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1230
Synthesis and Comparative Machining Characterization of A356 -
Graphite, A356 – SiC and A356 – CaSiO3 Composites
Rajesh Kambala1, P. Suresh Babu2
1Student, Dept. of Mechanical Engineering, Narasaraopeta Engineering College, Andhra Pradesh, India
2Associate professor, dept. of Mechanical Engineering, Narasaraopeta Engineering College, Andhra Pradesh, India
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Abstract - Metal matrix composites play an important role in
automotive engineering, railway or subway cars, aerospace
industry and military. At present investigation, the specimens
of aluminum [A356] reinforced separately with 5% graphite
powder,5% SiC powder and 5% calcium silicate powder were
prepared using stir casting machine. These three different
types of specimens were tested in on lathe for machinability
studies in which cutting forces and machining capabilitieslike
metal removal rate, surface roughness and also power
consumption were studied at variouscuttingspeedsand depth
of cuts.
The cutting forces have shown increasing trend up to
a speed of 50 m/min due to work hardening of composite and
then decreased at high speeds due to softening of material.
Metal removal rate and power consumption has shown
increasing trend with respect to cutting speed as wellasdepth
of cut. Machining times were calculated using CATIA V5R20
software and they were compared with practical values.
A356- Graphite composite have shown better machining
characteristics compared to other two composites
Key Words: (Size 10 & Bold) Key word1, Key
word2, Key word3, etc (Minimum 5 to 8 key words)…
1. INTRODUCTION
1.1 Metal Matrix Composites
Now a days metal matrix composites (MMCs) are
replacing conventional materials in many applications
because of their superior properties such as high strengthto
weight ratio, hardness, stiffness and wear and corrosion
resistances over conventional materials. Silicon carbide
particle (SiC) reinforced aluminium-based MMCsareamong
the most commonMMCand commerciallyavailableones due
to their economical production.In addition,thedevelopment
of stir casting route for synthesis has brought down their
cost to an acceptable level compared to those processed by
powder metallurgy and spray casting process Particulate
metal matrix composites have produced economically by
conventional casting techniques. However, the stiffness,
hardness and strength to weight ratio of cast MMCs are
increased, but a substantial decrease in ductility has
obtained.
Composites are material consisting two or more
natural or artificial materials to maximize their useful
properties and minimize their weaknesses. Composites are
typically used in place of metals because they are equally
strong but much lighter. It consists of two or more distinct
phases (matrix phase and reinforcing phase/phases) where
individual phase retains its properties (physical,mechanical
and chemical).Propertiessuchashighstiffness,highstrength
to weightratio, low density, high temperature stability, high
electrical and thermal conductivity, adjustable coefficient of
thermal expansion, corrosion resistance, improved wear
resistance etc. make composites attractive materials.
The composite materials are classified into three
categories. They are Polymer Matrix Composites (PMC),
Metal Matrix Composites (MMC) and Ceramic Matrix
Composites (CMC) based on matrix phase .At present work
our experimental specimens are MMC’s and here matrix
material is A356 and graphite, SiC, CaSiO3 are the
reinforcement powders.
1.2 Machinability
Machinability is a consideration in the materials
selection process for different machine parts. The ease with
which a metal can be machined is one of theprinciplefactors
affecting a product's utility, quality and cost. The usefulness
of a means to predict machinability is obvious.
Unfortunately, machinability is so complex a subject that it
cannot be unambiguously defined. Depending on the
application, machinability may be seen in terms of tool wear
rate, total power consumption, attainable surface finish or
several other benchmarks.Machinability -thereforedepends
a great deal on the viewpoint of the observer; in fact, the
criteria for one application frequently conflict withthosefor
another.
At our present experiment the machining
capabilities of three different metal matrix composites were
tested at various cutting speeds and depth of cuts.
2. MATERIAL AND EXPERIMENTAL METHOD
The specimens used in these experimentsaremetal
matrix composites which are fabricated by reinforcing5% of
graphite or SiC or CaSiO3 powder of 40-50µ size into
aluminum [A356] using stir casting technique.
2.1 Matrix Material
Aluminiun[A356] is used as matrix material in this
experiment in which reinforcing powder is to be added
during its molten state. A356 is a grade ofaluniniumandthis
alloy consists 92.05% of Al, 7% of Cu , 0.35% of Mg ,0.1% of
Zn and 0.1% of Mn. The following factors should be
considered while choosing a matrix material.

 Formability
 Weldability
 Machinability
 Corrosion resistance
 Heat treating
The reasons for choosing A356 as matrix material are;
alloys have very good casting and machining characteristics.
Typically they are used in the heat-treated conditions.
Corrosion resistance is excellent and it has very good
weldability characteristics. Mechanical properties are rated
excellent particularly if given a solution and aging treatment.
The anodized appearance is gray in color. Typically thisalloy
is used in castings for aircraft parts, pump housings,
impellers, high velocity blowers and structural castings
where high strength is required. It can also be used as a
substitute for aluminum alloy 6061.The fact that 356 and
A356 have good castability makes it a logical choice for
intricate and complex castings where lightweight, pressure
tightness and excellent mechanical properties are needed.
2.2 Reinforcement Material
At this present work three different types of
reinforcement powders were used which were discussed
below
2.2.1 Graphite powder
The first type of specimen is fabricated by
reinforcing5% of graphite powder of particle size 40-50µ.
The key property of commercial graphite is given below.
Table – 1: Properties of graphite
Bulk density 1.3-1.95 [g/cm3]
Porosity 0.7-5.3 %
Young’s modules 8-15 [GPa]
Compressive strength 20-200[MPa]
Flexural strength 6.9-100 [MPa]
Coefficient of thermal
expansion
1.2-8.2 [X10-6 0c]
Thermal conductivity 25-470 [W/m K]
Specific heat capacity 710-830 /Kg K]
2.2.2 Silicon Carbide [Sic] Powder
5% of silicon carbide particles of size 40-50µ were added
into matrix material in second type of specimens. The
characteristics of silicon carbide were given below.
 Low density
 High strength
 Good high temperature strength (Reaction
bonded)
 Oxidation resistance (Reaction bonded
Excellent thermal shockresistance
 High hardness and wearresistance
 Excellent chemical resistance
 Low thermal expansion and high thermal
conductivity
2.23Calcium Silicate[CaSiO3] Powder
In third type of specimen reinforcement material is 5%of
calcium silicate powder of particle size 40-50µ.Itcanexhibit
high condutvity, high stability, high purity, good wear
resistance, low coefficient of thermal expansion and
resistant to oxidation at high temperature.
2.3 Stir Casting Method
The required three types of specimens were synthesized
using a bottom pouring type stir casting furnace which
contains the following components.
A graphite stirrer is used to mix the matrix phase in
molten state and preheated reinforcement powders
homogenously bymechanicalstirring.Itwillhavebothrotary
and reciprocating motions at a time. There is a separate unit
called stirrer height controller by means of which motion of
stirrer can be controlled. Melting furnace will heat the
crucible in which solid matrix material is converted into
molten metal. The reinforcement powder will be placed in
another preheated furnace from which powder is released
gradually into molten metal during the process of stirring.
There a measuring and control unit which displays the
temperature of furnace, melt, mould and reinforcement
powder and also stirring speed. By using this unit the above
parameters can be varied.Thefollowingprocedureshouldbe
fallowed to synthesize the required specimens using stir
casting machine.
Set the temperature of furnace, melt, die and
reinforcement powder according to the experimental
conditions given below. Cut the aluminium ingots of 356
gradesmall pieces enough to place into the crucible. Heatthe
matrix material to attain molten state up to 7900C. Place the

reinforcement powderinthecorrespondingfurnaceandheat
it up to 2000C to 3000C based on type of powder. Keep the
stirrer in ON position after the temperature of melt reached
to 7900C which enables the stirrer to mix the molten metal
with reinforcing powder homogeneously which is released
gradually into the crucible. Stirrer can also be moved up and
down by operating correspondingswitches.Afterthatswitch
on the pour button on control unit which enablesthepouring
of molten compositeinto the dieormouldandthenallowitto
solidify after that remove the solid shaft [required specimen
or work piece] from the die
Fig - 1: Stir casting machine
. Table – 2: Casting conditions
Furnace Temperature 8500C
Melt Temperature 7900C
Powder Temperature
2000C for graphite
3000C for SiC
4000C for CaSiO3
Mould Temperature 2500C
Pouring Temperature 7900C
Stirring Speed 400 rpm
Stirring Time 5 min
Fig – 2: Experimental Specimens
 A356+ [5% wt] Graphite composite
 A356+[5% wt] SiC composite
 A356+[5% wt]CaSiO3 composite
2.4 Machinability Test
The turning experiments were carried out for the
three by using HSS tool bits inaautomaticlathemachine.The
machining trials were performed with three cutting speeds
(N) 202, 303, and 455 r.p.m with a constant feed (f) of 0.4
mm/rev and a depth of cut of 0.5 mm under dry
environment. Cutting forces were measured on lathe tool
dynamometerfacilityatNECcollege.Atthesametimesurface
roughness values were also measured. The above machining
trails were repeated with three depths of cut [Dc] 0.5, 0.75,1
mm at a constant speed of 303 r.p.m and constant feed of 0.4
mm/min.
Fig - 4: Experimental set up
The above procedure is repeated for three different
specimens
2.4.1 Input Parameters
We have given various cutting speeds, depth of cuts
and feed as input parameters in order calculate various
machining characteristics.
 Cutting speed [rpm]
 Depth of cut [mm]
 Feed [mm/rev]
2.4.2 Responses Measured
During the machining, the values of cutting forces
developed are taken from lathe tool dynamometer and by
using these values metal removal rate and power were
calculated. Surface roughness was also checked.
 Axial force [Fx] in N
 Cutting force or Tangential force [Fy] in N
 Radial force [Fz] in N

 Power [P] in W
 Metal removal rate [MRR] in mm3/min
 Surface roughness in µm
Fig – 3: lathe tool dynamometer
2.5 Determination of Machining Time Using CATIA
The following procedure should be followed this
experiment was done using CATIAV5R20.Opentwoseparate
components one is for design part and other one is for stock
element. Design the required shaft and stock part according
to the dimensions of real specimens. Apply material tooth of
them Unhide the sketch of the both parts which must visible
during part selection. GO to machining and select lathe
machining. Click on the partoperationandselecttypeoflathe
machine and give maximum speed. The icons related to
several lathe operations will be appeared on the screen and
click on rough turning and give values of depth of cut, speed
and feed as input. Select the tool geometry, axes. Give the
path for both design part and stock and run the
programme,we will get machining time as output at a given
feed rate. Repeat the above procedure for various cutting
speeds and depth of cuts according to the practical
experiment
Fig -3: Design part with stock
Fig – 4: applying material
Fig – 6: output machining time
Table – 3: machining time in sec [practical vs. CATIA]
2.6 Results and Discussions
After loading the component on the lathe machine plane
turning operation has performed and specimen is divided
into six divisions to perform six operations by varying speed
and depth of cut parameters. Feed is kept constant in every
time.
2.6.1 Effect Of Speed On Cutting Forces
this situation turning operation is carried out at
different cutting speeds like 202, 303 and 455 rpms at the
same time feed and depth of cut are kept constant. Cutting
forces values are taken from lathe tool dynamometer
Table – 3: Effect of Speed on Cutting Forces
Cutting speed
(rpm)
Fx
(N)
Fy
(N)
Fz
(N)
For A356+[5% wt] Graphite composite
202 39.24 147.15 176.58
303 78.48 235.44 225.63
455 68.48 196.2 186.01
For A356+[5% wt] SiC composite
202 117 304 255
303 137 343 294
455 78 215 186
For A356+[5% wt]CaSiO3 composite
Speed
[rpm]
A356+Graphite A356+SiC A356+CaSiO3
p C P C p c
202 151.12 148.51 145 148.51 153 148.51
303 95.34 99.00 95 99.00 98 99.00
455 62.12 65.93 65 65.93 64 65.93

202 58.86 294.3 245.25
303 176.58 382.59 274
455 117.72 313.92 255
2.6.2 Effect of depth of cut on cutting forces:
Under this situation turning operationiscarriedout
by giving different depth of cuts like 0.5, 0.75 and 1 mm.
while cutting speed and feed are constant. Again cutting
forces values are taken from lathe tool dynamometer
Table – 4: Effect of depth of cut on Cutting Forces
Depth of
Cut
(mm)
Fx
(N)
Fy
(N)
Fz
(N)
For A356+ [5% wt] Graphite composite
0.5 88.29 196.01 184
0.75 92 206.2 215.82
1.0 147.15 294.3 274.68
For A356+ [5% wt] SiC composite
0.5 156 196.01 313
0.75 176 226.2 333
1.0 186 294.3 372
For A356+ [5% wt] CaSiO3 composite
0.5 58.86 196.2 225.63
0.75 137.34 304.11 284.49
1.0 147.15 333.54 313.92
2.6.3 Machining Results
By using the values collected from lathe tool
dynamometer we calculated power and material removal
rate and by using surf test instrument we checked surface
roughness of machining specimen.
Table – 5: Effect of speed on machining capabilities
Cutting speed
(rpm)
Power
(W)
MRR
(mm3/min)
Surface
roughness
(µm)
202 71.5 8.42 25.5
303 171.6 14.52 18
455 215 20.5 14.55
For A356+ [5% wt] SiC composite
202 174.33 8.75 29.09
303 223.83 13.92 19.01
455 246 18.19 17.02
For A356+ [5% wt]CaSiO3 composite
202 147.83 9.138 28.16
303 288.16 13.70 25.54
455 354.6 20.08 15.27
Table – 5: Effect of depth of cut on machining capabilities
Depth of
cut
(mm)
Power
(W)
MRR
(mm3/min)
Surface
roughness
(µm)
0.5 101.16 8.42 11.22
0.75 143 14.52 13.16
1.0 322.5 18.276 18.06
For A356+[5% wt] SiC composite
0.5 204.16 8.75 13.67
0.75 268.92 13.92 14.08
1.0 403.83 16.15 25.40
For A356+[5% wt] CaSiO3 composite
0.5 54 6.092 10.17
0.75 229 13.707 14.77
1.0 377 16.09 21.16
Graph – 1: Axial force Vs. Speed
Graph – 2: Tangential force Vs. Speed

Graph – 3: Radial force Vs. Speed
The above three graphs show the comparision of
cutting forces at diferent cutting speeds in which all the
cutting forces increases up to a speed of 303 rpm and then
decreased at higher speeds.The cutting forces developed in
graphitecompositearelessthanthatofothertwocomposites
Graph – 4: axial force Vs. Depth of cut
Graph – 5: Tangential Force Vs. Depth Of Cut
Graph – 6: Radial Force Vs. Depth Of Cut
Theabovethreegraphsshowthecomparisoncutting
forces at various depths of cuts. The induced cutting forces h
ofas been completed, Out of three compositesSiCcomposites
involves more cutting forces than the other two composites.
Graph – 7: MRR vs. Speed
Graph – 8: MRR Vs. Depth of cut
Graph – 9: Power vs. Speed
Graph – 10: Power vs. Depth of cut

Graph – 11: Surface roughness vs. Speed
Graph – 12: Surface roughness vs. Depth of cut
From the above graphs it is clear that MRR,
power,increases non linearlywiththecuttingspeedwhereas
surface roughness is decreased case of all the three
composites.It is also noticed that power, MRR suface
roughneshh were incresed with depth of cut.
3. CONCLUSIONS
 A356matrix composites have successfullyprepared
by using stir casting technique.
 Cutting forces have shown increasing trend up to a
speed of 50m/min due to work hardening of the
composite, and then decreased at high speed due to
softening of the material.
 MRR has shown increasing trend with respect to
speed whereas surface roughness has shown
decreasing trend
 Due to increase in depth of cut, the tool has to deal
with higher volume of material which will
ultimately result in an increase in the force as well
as power consumption.
 MRR and surface roughness has shown increasing
trend with respect to depth of cut for all the three
composites.
 Machining time was calculated using CATIA and
compared with practical values. It will take less
machining time if use corresponding tool
 A356-graphite composite has shown best
machinability characteristicswhen comparedother
two to composites.
REFERENCES
[1] Anil K.C, M.G Vikas, shanmuka teja, K.V srinivasarao
“effect of cutting parameters on surface finish and
machinability graphite reinforced AI-8011 matrix
composite.
[2] Varun Nayyar and Jacek Kaminski.,(2012) “ An
Experimental Investigation On Graphitic Cast Iron
Grades;Flake,CompactedAndSpherodal GraphiteIronin
Continuous Machining Operations “
[3] Adbullah Altin (2013) “ The Effect Of Cutting Speed On
Cutting Forcesand Surface Finish When Milling
Chromium210 Cr 12steel Hard Facing With Uncoated
Cutting Tools”
[4] Surappa, M.K. and Rohatgi, R.K., (1981)Journal of
Material Science, Vol. 61,983-993
[5] Mechanics of composite materials by AUTAR K. KAW

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