Effect of Abrasive Waterjet Machining Parameters on Hybrid AA6061-B4C- CNT Composites

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ScienceDirect Materials Today: Proceedings 5 (2018) 13438–13450

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ICMMM - 2017

Effect of Abrasive Waterjet Machining Parameters on Hybrid AA6061-B4C- CNT Composites A.Gnanavelbabua*, P.Saravananb, K.Rajkumarc, S.Karthikeyand, R.Baskarane a,e

Associate Professor, Department of Industrial Engineering, Anna University Chennai-600025, Tamilnadu, India

b c

Research Scholar, Department of Industrial Engineering, Anna University Chennai-600025, Tamilnadu, India

Associate Professor, Department of Mechanical Engineering, SSN College of Engineering, Kalavakkam-603110,Tamilnadu, India d

Professor, Centre for Innovative Manufacturing Research, VIT University, Vellore-632014, Tamilnadu, India

Abstract In general, Metal Matrix Composites (MMC)are very hard to machine using conventional machining due to complexity towards elevated temperature and tool wear issues. Abrasive water jet machining is a very efficient machining process which overcomes tool wear issues and cutting temperature issues. In this research study,AA6061-B4C- CNT was machined using Abrasive Waterjet Machining under different process parameters such as mesh size, abrasive flow rate, pressure and traverse speed. Boron carbide was used as reinforcement and Carbon Nanotube (CNT) was used as a solid lubricant. Two different composition of boron carbide (5, 15 vol %) and CNT (5, 15vol %) with residual volume percentage of aluminium as a core material were fabricated using stir casting method. The Machining approach is based on the Taguchi L9 orthogonal array design to enhance the Abrasive waterjet process parameters effectively. Then the multiple responses were investigated such as kerf taper geometries (θ), surface roughness (Ra) and material removal rate (MRR). The features of different machined surface regions were studied using Scanning electron microscopy (SEM). The investigational results indicate that increasing reinforcement improves the kerf taper angle under the significant parameter of traverse speed and decreasing the reinforcement leads to the lower surface roughness under significant parameter of pressure and traverse speed. It was observed that increasing reinforcement increasing the Material Removal Rate under the significant contribution of reducing mesh size of abrasive particles and inclined velocity. © 2017 Elsevier Ltd. All rights reserved. Selection and/or Peer-review under responsibility of International Conference on Materials Manufacturing and Modelling (ICMMM - 2017).

Keywords:AWJM, Metal Matrix Composite, Aluminium, Boron Carbide, Carbon Nanotubes, Kerf, Surface roughness, MRR

1. Introduction Materials with unique metallurgical properties such as Metal Matrix Composites other super alloys were developed to produce extreme applications. Aluminium based MMC face machining difficulties while subjected to elevated cutting temperature and tool wear issues [1]. Researchers are showed much interest in *

Corresponding author. Tel.: +91-9551133779; E-mail address: [email protected] 2214-7853© 2017 Elsevier Ltd. All rights reserved. Selection and/or Peer-review under responsibility of International Conference on Materials Manufacturing and Modelling (ICMMM - 2017).

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employingAluminium Metal Matrix Composites (AMMC) in the field of aerospace, automotive and defense[2]. It exhibits superior properties that may not be found in the alloys. Moreover an addition of hard reinforcement to the composites leads to enhanced strength which results in difficult to machining[3]. Due to its enhanced material strength, it needs an unconventional machining process like EDM, ECM, EBM and LBM. EDM lacks with surface integrity such as quality and poor finish due to thermal cracking. Employing an ECM is easily but produced oxide layer on the surface as a result of corrosion which affects accuracy [4]. Another thermal process like LBM is based on the non-contact type machining method with better flexibility but producesmicro fissures on the cut surface [5]. Similarly high energy process such as EBM is also associated with thermal phenomena as like LBM and expensive [6]. The suitable machining process for MMC was found to be Abrasive water jet machining because of less thermal distortion and minimal induced stresses in the machined surface. Abrasive waterjet machining is an economical process to machining hard complex shapes using smaller cutting forces [7-9]. Boron carbide is discoveredas popular reinforcement particles for the metal matrix composites. In further, adding of solid lubricant like CNT provides an excellent strengthening effect to the metal. Hence this strong combination of reinforcement and solid lubricantprovides a better structural and strength physiognomies to the metal matrix as required for the advanced engineering applications. In general,Aluminium reinforced with boron carbide composite shows relatively enhanced physical and mechanical properties like strength to weight ratio, low wear rate and nominal friction coefficient than other reinforcement with aluminium matrix [10]. Solid lubricants like hBN acts a coolant while machining at elevated temperature and saved the material from rapid tool wear [11]. Hence abrasive water jet machining is more appropriate to machine the Al6061-B4C-CNT composite. The water carrying the garnet abrasive particles acts as a coolant in abrasive waterjet technology in order to eliminate heat issues. High energy of water jet and abrasive particles plays a key role in machining process. The machining performance ofAWJ machining mainly depends on the abrasive particle’s traverse speed and jet impact angles. A small cutting force is enough for material processing with huge advantages like nil thermal distortion and better adaptability [12, 13]. The quality of cutting evaluation is based on the surface roughness, waviness, angle of striations and MRR. The ultimate motto is to obtain smooth surface of cut region. Those better machining surface can be achieved by changing process parameters like abrasive flow rate, mesh size, pressure, traverse speed and standoff distance effectively [14-17]. In AWJ technology erosion process takes place in high speed. Hitting of Abrasive particles with high traverse speed and high impact angle leads to erosion of the machining surface. There are two modes of erosion takes place by abrasive particles in AWJ machining processes. Larger particle impact angle causes deformation wear mode and smaller particle impact angle causes cutting wear mode.[18]. Abrasive water jet machining uses different process parameters like mesh size, abrasive flow rate, pressure of water and traverse speed. The cumulative effects of these variables on the machining surface can efficientlymodifies the kerf width to be cut, material removal rate (MRR), and surface roughness of cut surface. It is claimed that increase in water pressure and abrasive flow rate increases the surface roughness considerably[19] and increase in traverse speed decreases surface roughness and increasesMRR [20]. Multifaceted of input variables in AJWM machining lead to complexity in selection of processes parameters. Taguchi based L9 orthogonal array is implemented in machining of Al-B4C-CNT. Then the experimental result was analyzed through ANOVAwhich produces the optimal significant parameter and its contribution towards the each response. Most of literatures were targeted in the area of AWJM of brittle materials. There arevery less number of research work has been reported particularly for Abrasive watejet machining on metal matrix hybrid reinforced composites. This research work demonstrates the effects of AWJM machining of Al-B4C-CNT parameters and its influences on kerf geometry (θ), surface roughness (Ra) and MRR. 2. Experimental Procedure In this work, Al6061-B4C-CNT of two different compositions was machined usingabrasive water jet machining. Aluminiummetal matrix composites were fabricated with the composition of boron carbide (5, 15vol %) and CNT (5, 15vol %). It is denoted as Composition A (5% boron carbide-5%CNT) and Composition B (15% boron carbide15%CNT) respectively in this paper. Stir casting technique is employed for the fabrication of Composites. T6 heat

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treatment was carried out to enhance the mechanical properties of Aluminium based metal matrix composites. The machining experiments were carried out using abrasive water jet machine manufactured by OMAX Corporation which is shown in figure 1. Taguchi based L9 orthogonal array was used to implement different process parameters on AWJ machining. Table.1 shows the process parameters and its values used in the machining process. Table 1. Parameters and factors Oriface Diameter

0.25 mm

Nozzle diameter

0.75 mm

Focusing tube length

75mm

Focusing tube Diameter

1mm

Impact angle

90°

Abrasive Type

Garnet

Abrasive mesh size

80,100,120 #

Abrasive flow rate

240,340,440 g/min

Pump Pressure

125,200,275 MPa

Traverse Speed

60,90,120 mm/min

Standoff Distance

1.5 mm

Fig. 1 Precision Abrasive Waterjet Machining Center manufactured by OMAX Corporation (Model: 2626)

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3. EXPERIMENTAL RESULTS AND DISCUSSIONS 3.1. Composition A By using Taguchi L9 orthogonal method with different process parameters, nine cuts were machined in the Composition A (5% boron carbide-5%CNT) under the suitable environmental condition which is shown in table 2. Table 2 Measurement of Kerf taper angle, Surface roughness and MRR

Sl.No

Mesh Size (#)

Abrasive Flow Rate (g/min)

Pressure (MPa)

Traverse Speed (mm/min)

Kerf Taper Ѳ (Degrees)

MRR Roughness mm3/min Ra

1

120

240

275

90

0.265

11.1

2

120

340

125

120

0.288

13.51

3.666 3.176

3

120

440

200

60

0.146

7.362

3.871

4

100

440

125

90

0.181

10.29

3.862

5

100

340

275

60

0.149

7.749

4.077

6

100

240

200

120

0.281

13.48

3.127

7

80

240

125

60

0.141

7.146

4.522

8

80

340

200

90

0.272

11.25

3.276

9

80

440

275

120

0.301

14.99

3.012

After the machining, cut surfaces were examined using Scanning electron microscopy (SEM) for microstructural analysis and Kerf width were measured using Video measurement system for kerf taper angle. Later surface roughness was measured using portable stylus-type contact roughness meter. MRR was calculated using the Kerf width, traverse speed and depth of penetration. The calculation of kerf taper, MRR and surface roughness was shown in above table 2. Response surface methodology approach is the technique for describing the correlation between different process parameters with various cutting conditions and determining the various effects of the process parameters on the mutual responses [21]. 3.1.1. Kerf Geometry for Composition A Rational Video Measurement system 2010-F was used to measure kerf geometry. Typical view of kerf width is shown in figure 2. The kerf top and kerfbottom of each cut was measured to calculate the kerf taper angle. (1)

Where t is the width or thickness of the material t = 5 mm; Wt is the Kerf Top; Wb is the Kerf Bottom

Fig. 2 Typical view of Lowest Kerf Width of Composition A

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The Top kerf is obviously wider than bottom kerf due to increase in pressure, which is a vital factor in Abrasive water jet machining. Due to the pressure factor, Kerf taper is produced. The largest kerf taper angle ratio affects the straightness of cutting and its results in poor dimensional quality. It is evident that low water pressure (125MPa) and low traverse speed (60 mm/min) were produced the minimum kerf taper angle of θ = 0.141 which is shown in figure 3. When traverse speed increases, it will increase the slope of kerf wall due to abrasives strike on target which produces narrower slot. Analysis of variance (ANOVA) was used to analyze the results of Kerf taper angle which is shown in table 3. Table 3 ANOVA for Kerf Taper Angle S.No

Source

1 2

Model A-Mesh Size

Sum of Squares 0.034 3.750E-005

3 4 5

B-Abrasive Flow rate C-Pressure D-Traverse rate

5.802E-004 0.031 3.851E-003

Mean Square 0.034 3.750E-005

F Value

df 4 1

8.79 0.065

P- Value Prob > F 0.0455 0.8021

1 1 1

5.802E-004 0.031 3.851E-003

3.14 9.14 8.69

0.0983 0.0091 0.0106

The Model F-value of 8.79 implies the model is significant. Values of "Prob> F" less than 0.04500 indicates that model terms are significantly contributed. In this case, C-Pressure is significant model terms.

Fig. 3 3D Surface of Kerf Taper angle for Composition A

3.1.2. Surface Roughnessfor Composition A Portable stylus-type contact roughness meter was used for the measurement of roughness. The profilometer was calibrated with traverse speed 1mm/sec, cutoff length of 0.8 mm, and 3 mm estimate length. Measurements of roughness are taken in the transverse direction of the work pieces and it is repeated twice, and the average of two measurements of surface roughness was calculated. Analysis of variance (ANOVA) was used to analyze the results of Surface roughness which is shown in table 4.The Regression model for Surface roughness in figure 4 shows the response surface graphs which are plotted to achieve minimum surface roughness with different combinations of AWJM process parameter during machining of Composition A. Analysis of variance (ANOVA) was used to analyze the results of Surface roughness which is shown in table 4.

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Table 4 ANOVA for Surface Roughness S.No

Source

Sum of Squares

df

Mean Square

F Value

p-value Prob > F

1

Model

1.82

4

0.46

7.25

0.0406

2

A-Mesh Size

1.568E-003

1

1.568E-003

0.25

0.8822

3

B-Abrasive Flow rate

0.054

1

0.054

0.86

0.4060

4

C-Pressure

0.011

1

0.011

1.72

0.2602

5

D-Traverse rate

1.66

1

1.66

26.38

<0.001

The Model F-value of 7.25 implies the model is significant. Values of "Prob> F" less than 0.001 indicates that model terms are significantly contributed. In this case, D-Traverse speed is significant model terms. Values greater than 0.1000 indicate the model terms are not significant. It is evident that high traverse speed (120 mm/min) and highwater pressure (275 MPa) were produced the surface roughness of Ra = 3.012 which is shown in figure 5. .

Fig. 4 3D Surface of Surface Roughness for Composition A

3.1.3. Material Removal Rate for Composition A Material removal rate (MRR) was calculated using Kerf width, traverse speed and depth of penetration. Moreover standoff distance plays a major role in material removal rate (MRR). Material removal rate increases with standoff distance, because of penetration depth creating craters in working surface. Material removal was calculated using following formula, Material Removal Rate (MRR) = ht.W.Vt(2) W= Kerf Width = (Wt + Wb)/2 Wt is the Kerf Top; Wb is the Kerf Bottom Vt= Traverse rate (m/min); ht= Depth of Penetration (ht=5mm) Analysis of variance (ANOVA) was used to analyze the results of Material removal rate which is shown in table 5.

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Source

Sum of Squares

df

Mean Square

F Value

p-value Prob > F

1

Model

66.76

4

16.69

162.70

0.0512

2

A-Mesh Size

0.34

1

0.34

3.27

0.0150

3

B-Abrasive Flow rate

0.14

1

0.14

1.37

0.3669

4 5

C-Pressure D-Traverse rate

1.39 64.89

1 1

1.39 64.89

13.55 362.59

0.0212 < 0.0001

The Model F-value of 162.50 implies the model is significant. Values of "Prob> F" less than 0.0500 indicates that model terms are significantly contributed. In this case, A-Mesh size, C- pressure and D-Traverse speed are significant model terms. It is evident that low mesh size (80#), high traverse speed (120 mm/min) and highwater pressure (275 MPa) were produced the maximum material removal rate of 14.99mm3/min which is shown in figure5.

Fig. 5 3D Surface of Material Removal Rate for Composition A

3.1.4. Surface Topographyfor Composition A The machined surface of samples having higher roughness and lower roughness under 200µm in SEM was shown in figure 6 and figure 7. There are two distinct zones were found as: Smooth machining region (SMR) which is present in lower roughness sample and Rough machining region (RMR) which is present in higher roughness sample. Smooth machining region was obtained at higher cutting angle zone and whereas rough machining region was obtained at reversal jet deflection. The width of the smooth cut region increases with increase in traverse rate, because of higher depth of cut. The cutting wear and deformation wear found as a patchy scar in rough cutting region due to high pressure and low traverse speed.

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Fig. 6 Cut Surface of higher Roughness

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Fig. 7 Cut Surface of lower Roughness

3.2. Composition B By using Taguchi L9 orthogonal method with different process parameters, nine cuts were machinedin CompositionB (15% boron carbide- 15%CNT) under suitable environmental condition which is shown in table 6. Table 6 Measurement of Kerf taper angle, Surface roughness and MRR of Composition B

Sl.No

Mesh Size (#)

Abrasive Flow Rate (g/min)

Pressure (MPa)

Traverse Speed (mm/min)

Kerf Taper Ѳ (Degrees) 0.168

MRR Roughness mm3/min Ra

1

120

240

275

90

11.42

3.544

2

120

340

125

120

0.243

14.78

3.125

3

120

440

200

60

0.078

8.104

3.718

4

100

440

125

90

0.158

11.46

3.745

5

100

340

275

60

0.065

8.257

3.92

6

100

240

200

120

0.256

15.23

3.352

7

80

240

125

60

0.075

7.704

4.225

8

80

340

200

90

0.172

11.65

3.484

9

80

440

275

120

0.275

16.26

3.255

3.2.1. Kerf Geometry for Composition B The Kerf geometry was measured using Rational VMS 2010-F which is shown in figure 8. The top kerf and bottom kerf of each cut was measured to calculate the kerf taper angle for each cut. (3)

Where t is the width or thickness of the material t = 5 mm Wt is the KerfTop Wb is the KerfBottom

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Fig. 8 Typical view of Lowest Kerf Width for Composition B

Analysis of variance (ANOVA) was used to analyze the results of Kerf taper angle which is shown in table 7. Table 7 ANOVA for Kerf Taper Angle S.No

Source

1

Model

Sum of Squares 0.052

Mean Square 0.013

F Value

df 4

542.83

P- Value Prob > F <0.0001

2

A-Mesh Size

8.817E-005

1

8.817E-005

3.67

0.1278

3 4

B-Abrasive Flow rate C-Pressure

8.007E-005 4.507E-004

1 1

8.007E-005 4.507E-004

3.36 18.77

0.1408 0.0123

5

D-Traverse rate

0.052

1

0.052

2145.54

<0.0001

In this case, D-Traverse speed is significant model terms.It is evident that high water pressure (275MPa) and low traverse speed (60 mm/min) were produced the minimum kerf taper angle of θ = 0.065 which is shown in figure 10. Adding the volume fraction of reinforcement and solid lubricant required the water pressure parameter higher to get a minimized kerf taper angle when compared to composition A with less volume fraction of reinforcement and solid lubricant.

Fig. 9 3D Surface of Kerf Taper angle for Composition B

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3.2.2. Surface Roughness for Composition B Analysis of variance (ANOVA) was used to analyze the results of Surface roughness for composition B which is shown in table 8. Table 8 ANOVA for Surface Roughness S.No

Source

Sum of Squares

df

Mean Square

F Value

p-value Prob > F

1

Model

0.86

4

0.227

9.85

0.0239

2

A-Mesh Size

0.052

1

0.052

2.53

0.1867

3 4 5

B-Abrasive Flow rate C-Pressure D-Traverse rate

0.027 0.024 0.76

1 1 1

0.027 0.024 0.76

1.24 1.08 34.55

0.3286 0.3583 0.0042

In this case, D-Traverse speed is significant model terms. It is evident that high traverse speed (120 mm/min) and lowwater pressure (125 MPa) were produced the surface roughness of Ra = 3.125 which is shown in figure 10. The material added with volume fraction of reinforcement required lower pressure to produce a minimum roughness.

Fig. 10 3D Surface of Surface Roughness for Composition B

3.2.3. Material Removal Rate for Composition B Analysis of variance (ANOVA) was used to analyze the results of Material removal rate for composition B which is shown in table 9. Table 9 ANOVA for MRR S.No

Source

Sum of Squares

df

Mean Square

F Value

p-value Prob > F

1

Model

83.56

4

20.89

658.61

<0.0001

2

A-Mesh Size

0.29

1

0.29

9.02

0.0398

3

B-Abrasive Flow rate

0.36

1

0.36

11.36

0.0280

4

C-Pressure

0.66

1

0.66

20.67

0.0104

5

D-Traverse rate

82.25

1

82.25

2581.38

< 0.0001

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In this case, D-Traverse speed is significant model terms. It is evident that low mesh size (80#), high traverse speed (120 mm/min) and high water pressure (275 MPa) were produced the maximum material removal rate of 16.26 mm3/min which is shown in figure 11.

Fig. 11 3D Surface of Material Removal Rate for Composition A

3.2.4. Surface Topographyfor Composition B The machined surface of samples having lower roughness and higher roughness under 200µm in SEM was shown in figure 12 and figure 13. In this SEM image, particulates are visible and patchy. The lower roughness leads to the smoothness of cut by the significant process parameter of traverse speed. Traverse speed and plays a significant role in contributing towards roughness of the material.

Fig. 12 Cut Surface of Lower Roughness

Fig.13Cut Surface of higher Roughness

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4. Conclusions In this research, Kerf taper angle, surface roughness (Ra), topographical analysis and Material Removal Rate (MRR) of Al-B4C-CNT Composite were investigated using Abrasive water jet machining. By the summarized results from above responses, the following conclusions was made and recommended. 1. For Composition A, low water pressure (125 MPa) and low traverse speed (60 mm/min) were produced the minimum kerf taper angle of θ = 0.141. For Composition B, high water pressure (275 MPa) and low traverse speed (60 mm/min) were produced the minimum kerf taper angle of θ = 0.065. It is conclusive that increasing reinforcement improves the kerf taper angle with significant parameter of traverse speed. 2. For Composition A, high traverse speed (120 mm/min) and high water pressure (275 MPa) were produced the surface roughness of Ra = 3.012. For Composition B, high traverse speed (120 mm/min) and low water pressure (125 MPa) were produced the surface roughness of Ra = 3.125. It is evident that decreasing the reinforcement leads to the lower surface roughness. 3. For Composition A, low mesh size (80#), high traverse speed (120 mm/min) and high water pressure (275 MPa) were produced the maximum material removal rate of 14.99 mm3/min. For Composition B, low mesh size (80#), high traverse speed (120 mm/min) and high water pressure (275 MPa) were produced the maximum material removal rate of 16.26 mm3/min. It is obvious that increasing reinforcement increasing the Material Removal Rate with significant contribution of reducing mesh size of abrasive particles. 4. Microstructural analyses of machined surfaces revealed that Smooth Cutting Region was found at less reinforced composite and Rough Cutting Region. Smooth Cutting region (SCR) was found at higher reinforced composite. References [1] Arola, D., Alade, A. E., & Weber, W. (2006). Improving fatigue strength of metals using abrasive waterjet peening. 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