24-12-2012, 05:03 PM
Milling and Drilling of Metal Particle Reinforced Nano Composite Materials
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ABSTRACT:
In the present work conventional Milling & Drilling operation for Alumina particle reinforced Epoxy Composites where alumina particles act as fibres oriented randomly & Epoxy Resin (Araldite CY 230) as the matrix. Rectangular samples were made with 0%, 3% & 5% reinforcements.The cutting tool used for both milling & drilling is a High Speed Steel (HSS) tool of diameter 5mm. Curves were obtained between Cutting Force (Fc) and percentage of particle reinforcement keeping the parameters like speed, feed & depth of cut constant. After machining the composites, the surface roughness was also measured.
INTRODUCTION:
Composite is a material formed with two or more components, combined as a structural unit. One of the constituent materials acts as a fibre & the other acts as reinforcement. The role of matrix is to distribute the stress to the reinforcement material & to provide the final shape to the part. The role of reinforcement is to provide the composite high mechanical properties. The relative content of reinforcement & matrix can be expressed as :Vf = (reinforcement vol.)/(composite Vol) and Vm= (matrix vol.)/(composite vol.), where Vf + Vm = 1. The classification of composite materials can be done on the basis of matrix material used i.e. PMC, MMC & CMC.
Polymer Matrix Composites are most commonly used due to their properties like high specific mechanical properties & relatively low cost. PMC are knows as Fibre Reinforced Plastics or FRPs in short. Fibres can be Glass, Aramid or Carbon. The fibres can be short, long, particle shaped. Also the orientation can be unidirectional or random. Highest mechanical properties are provided basically by the unidirectional fibres.
The Aluminium matrix composites show very desirable properties like excellent wear resistance, high specific strength, low weight due to which they are a reason for great interest. Also they have low density, high strength to weight ratio as compared to ferrous alloys. They are also cheaper & lighter than metals such as Mg & Ti.
MATERIALS& METHODS:
Materials:
Epoxy ResinCY230:
Epoxy resins are widely used for industrial purposes as they possess a high strength and adhesiveness.Araldite CY230, purchased from M/s S&S Polymers Chennai, India was used in this experiment.
Hardener HY951:
The Hardener HY 951 used with the epoxy resin cy230 acts as the curing agent, was purchased from M/s S& S Polymers Chennai, India.
CONCLUSION:
The current work presented an approach to conventional Milling & Drilling of Alumina Nano particle reinforced epoxy composites. The vol. of fibre was varied as 0%, 3% & 5%. The feed rate for all the three samples was kept constant during milling & it was observed that with increase in vol. fraction of alumina particles, Cutting Force (Fc) increases gradually &also with increase in speed (RPM) of the milling machine. The surface roughness also increased with the increase in vol. of fibre. For drilling operation, the speed was kept constant for all three samples i.e. 1500 RPM. The feed rate was maintained at 0.3 mm/rev.