2. LITERATURE SURVEY: Metal matrix composites are being used in various fields such as marine, automobile, structural, aerospace space and other considerable applications because it provides unique balance of physical and mechanical properties of both materials used. In recent days MMC’s are produced using various technical specifications and techniques in order to meet the demand in market that includes properties such as higher strength and toughness, higher wear resistance, less weight and density and also to withstand thermal stability at lowest possible cost. [7] Aluminium and its alloys have continued to maintain their mark as the matrix material most in demand for the development of Metal Matrix Composites (MMCs). This is primarily due …show more content…
The LM6 alloy possesses exceptional fluidity so that it is capable of producing intricate castings of thin sections. LM6 is especially suited to castings that need to be welded although special care is needed when machining. Carbide-tipped tools with large rake angles and relatively low cutting speeds give comparatively good machining results provided cutting lubricant and coolant are employed in the machining process. Some of the applications of LM6 alloy are marine on-deck castings, water-cooled and inlet manifolds, motor housings, doors, chemical equipment, dye and food equipment, and tools. [9, …show more content…
Greater attention is given to surface roughness as surface finish influences mechanical properties fatigue behavior, wear, corrosion, lubrication and electrical conductivity [13]. The mathematical relationship between responses and machining parameters was established for Al/SiC (5%) and Al/SiC (10%) using the multiple regression analysis. In this research, the correlation between the process parameters cutting speed, feed rate, depth of cut and surface roughness are established. The multiple linear regression models were obtained using statistical software MINITAB. [14] Mathematical model for any optimization problem involves an objective function, parameters to be optimized and some physical constraints for a more realistic output. This research work is to predict optimized cutting parameters and get the desired surface roughness values in minimum machining time for the proposed work materials. Based on the effect of cutting parameters on the surface roughness, it is found that the feed and depth of cut are directly proportional to the surface roughness and the cutting speed is inversely proportional to the surface roughness. Based on these facts, empirical relations are formed. [15,
3D printing is primarily for rapid part prototyping and small-run production in a variety of industries. In the meantime, the term additive manufacturing has come to represent the use of 3D printing to create metallic components and final parts, differentiating from conventional subtractive manufacturing processes. 3D printing uses computer-generated designs to create build paths that reproduce a digital model through consolidation of materials with an energy source. The process typically uses a laser, a binder or an electron beam that solidifies material as it is directed along scanned over a pre-placed layer or the build path of material. This method has been used successfully with metals, polymers and ceramics. Metals are still in their infancy in terms of finished part production. Metallic parts produced with 3D printing frequently require additio...
Before a metal piece or metal alloy can be used in any given application, whether it is a construction project or anything else, it might be necessary to cut the material to the right shape and size. One may need to cut metal into pieces of different sizes and shapes according to the end use.
The machinability of copper and copper alloys is improved by lead, sulfur, tellurium, and zinc while it deteriorates when tin and iron are added. Lead in brass alloys with concentrations around 2 wt%, improves machinability by acting as a microscopic chip breaker, and tool lubricant, while they increase the brittleness of the alloy [17]. Lead additions are used to improve machinability. The lead is insoluble in the solid brass and segregates as small globules that help the swarf to break up in to small pieces and may also help to lubricate the cutting tool action. The addition of lead is however, affect cold ductility which may control both the way in which material is produced and the extent to which it can be post-formed after machining
A wide variety of coating alloys and wrought alloys can be prepared that give the metal greater strength, castability, or resistance to corrosion or high temperatures. Some new alloys can be used as armor plate for tanks, personnel carriers, and other military vehicles.
Milling offers the advantages of being highly precise and having much smoother surface finish (surface roughness of easily around 1 µm ) compared to powder bed fusion additive manufacturing (layer thickness in the range of 20 µm and above; surface roughness of 15 µm and above ). Flat surfaces and sharp corners can be obtained with CNC milling. Similarly, features such as threads and holes are more accurately created through
Tool wear is a problem in machining titanium alloy, so it is of great importance to find out the wear mechanism of cutting tools in order to improve the cutting tool life time. The mechanism controlling the wear of cemented carbide and influence of cutting parameters on different wear modes in machining Ti6Al4V has been investigated in this paper. Diffusion and chemical wear at high cutting speed and feed rate and attrition in low speed and feed rate is suggested to be the dominant wear mechanism in this case.
Composite materials have become extremely useful and since been adapted for aviation. They have been in development ever since the use of aluminum in the early 1920’s. Composites are components that are mixtures of two or more inorganic or organic compounds. One material acts as a matrix, which is the compound that keeps everything together, while the other material provides a reinforcement, in the form of fibers embedded in the matrix.
it is lighter than aluminium, and is used in alloys used for aircraft, car engine casings, and missile construction
In addition, the integrity of the underlying metal is unaffected by paint chips (“The Institute of Materials,” n.d.). Further, the effect of sunlight-induced ultraviolet degradation is minimal. Signal transmission and reception is maximized by the high thermal conductivity of the metal. The latter also saves on complexity in fabrication and weight issues since a single-wire electrical system can be utilized (Whetstone, 1999). Moreover, the material requires less filling and sanding activities, thus enabling the designers to predetermine the smoothness of the
The connecting rod or con rod connects the piston to the crank or crank shaft. Together with the crank, they form a simple mechanism that converts reciprocating motion into rotating motion. As a connecting rod is rigid, it may transmit either a push or a pull and so the rod may rotate the crank through both halves of a revolution, i.e. piston pushing and piston pulling. In modern automotive internal combustion engines, the connecting rods are most usually made of steel for production engines, but can be made of T6-2024 and T651-7075 aluminum alloys, or titanium. There are different types of materials and production methods used in the creation of connecting rods. The most common types of connecting rods are steel and aluminum. The most common type of manufacturing processes is casting, forging and powdered metallurgy. Connecting rods are subject to tension and compression loads. A connecting rod is an engine component that transfers motion from the piston to the crankshaft and functions as a lever arm. Connecting rods are commonly made from cast aluminum alloy and are
Material handling system is an important equipment and in the design of an effective manufacturing design. One of the main tasks in material handling system design is the selection and setup involving apparatus, demanding comprehensive technical understanding along with methodical research. Material handling equipment selection is a very complex and tedious task. The main factors contributing to the complexity of the equipment selection problem is the constraints imposed by the facility and materials, a variety of disagreeing design and style requirements, anxiety inside functional environment, and some of equipment varieties in addition to designs accessible. In recent years, the equipment selection
Materials engineering and computer engineering are two of the modern examples of industrial engineering. Industrial engineers have the challenge of incorporating today’s leading technological advances with the production of them in manufacturing facilities. Their purpose is to maximize output, while minimizing the costs for materials and production. This is why industrial engineers must have knowledge of product development, materials processing, optimization, queuing theory, production techniques, and engineering economy. Industrial engineers must have adequate skills in computer aided design and computer aided manufacturing.
Metals possess many unique fundamental properties that make them an ideal material for use in a diverse range of applications. Many common place things know today are made from metals; bridges, utensils, vehicles of all modes of transport, contain some form of metal or metallic compound. Properties such as high tensile strength, high fracture toughness, malleability and availability are just some of the many advantages associated with metals. Metals, accompanied by their many compounds and alloys, similar properties, high and low corrosion levels, and affects, whether negative or positive, are a grand force to be reckoned with.
The optimization of cutting parameters during machining is a difficult task as it involves a number of aspects such as knowledge of machining, empirical equations of tool life, cutting forces, power consumed, machining surface finish etc. All these aspects should be considered during machining optimization to develop an effective optimization criterion (Sonmez et el, 1999). Manufacturing industries have long depended on the skill and experience of shop-floor machine-tool operators for optimal selection of cutting conditions and cutting tools. Many authors as early as in the 19th century like Taylor, 1907 have shown the optimization objective as specific cost from the beginning of the researches in this branch when the area of the art of cutting metals was looked on. This was also considered by to some of the most recent work (Liang et el, 2001; wang et el, 2002; Saravanan, 2003 and Cus and Balic,
Fortunately, during under-graduation, I got an opportunity to detect the optimum path of a process through my project “Design and Development of PCB Dual Head Drilling Machine”. Additionally, I became aware of a new subject called Six Sigma which aided me in intertwining new optimization techniques into my project to make the process effective. I optimized the creation...