Essay: STUDY THE EFFECT OF WEAR ON COMPOSITE MATERIAL TOOL

CHAPTER 1
INTRODUCTION
1.1 Overview :-
Composite material also called composition of materials or shortened to composites. Composite material are materials made from two or more constituent materials with significantly different physical or chemical properties, that when combined, produce a material with characteristics different from the individual components. The new material may be preferred for many reasons: common examples include materials which are stronger, lighter or less expensive when compared to traditional materials. Composites are made up of individual materials referred to as constituent materials. There are two main categories of constituent materials: matrix and reinforcement. At least one portion of each type is required. The matrix material surrounds and supports the reinforcement materials by maintaining their relative positions. The reinforcements impart their special mechanical and physical properties to enhance the matrix properties. A synergism produces material properties unavailable from the individual constituent materials, while the wide variety of matrix and strengthening materials allows the designer of the product or structure to choose an optimum combination.
A variety of moulding methods can be used according to the end-item design requirements. The principal factors impacting the methodology are the natures of the chosen matrix and reinforcement materials. Another important factor is the gross quantity of material to be produced. Large quantities can be used to justify high capital expenditures for rapid and automated manufacturing technology. Small production quantities are accommodated with lower capital expenditures but higher labour and tooling costs at a correspondingly slower rate. Many commercially produced composites use a polymer matrix material often called a resin solution.
1.2Composites materials:-
A “composite” is when two or more different materials are combined together to create a superior and unique material. The two phases that make up a composite are known as reinforcing phase and matrix phase. The reinforcing phase is embedded in the matrix phase and mainly provides strength to the matrix. The reinforcing phases usually found in composites are particles, fibers or sheets and the matrix materials can be of the form o polymers, ceramics or metals. The new material may be preferred for many reasons: common examples include materials which are stronger, lighter or less expensive when compared to traditional materials.
1.3Classification of Composites:-
‘ On the basis of Matrix:-
1. Ceramic Matrix Composites (CMC)
2. Metal Matrix Composites (MMC)
3. Hybrid Composite
‘ On the basis of Reinforcement:-
1. Particle reinforced composites
2. Fiber reinforced composites
‘ 1.3.1 On the basis of Matrix:-
‘ Ceramic Matrix Composites (CMC):- In that type of composite has ceramic materials as matrix phase. The matrix and fibers can consist of any ceramic material, as carbon and carbon fibers can also be considered a ceramic material. It is used for to increase the crack resistance or fracture toughness of material. Carbon(C), special silicon carbide (Sic), alumina (Al2O3) and mullite (Al2O3’SiO2) fibers are most commonly used for CMCs.
‘ Applications:-
‘ It is used as Heat shield systems of space vehicles
‘ Components of gas turbines such as combustion chambers, stator vanes and turbine blades.
‘ Components for burners, flame holders, and hot gas ducts,
‘ Brake disks and brake system components, which experience extreme thermal shock
‘ Components for slide bearings under heavy loads requiring high corrosion and wear resistance.
‘ Metal Matrix Composites (MMC):-
In metal matrix composite (MMC) is composite material with two constituent parts, one is a metal necessarily, the other one is material may be a different metal or another material, such as a ceramic or organic compound. MMCs are manufactured with aims to have high strength to weight ratio, high resistance to abrasion and corrosion, good dimensional stability, and high temperature operability. MMCs are used in industries like
automobile and aerospace. Mainly Aluminium and Copper are used as the metal matrix.
‘ Application:-
‘ Automobile and aerospace. ‘ Tank armors, sport cars, Specialized Bicycles.
‘ Hybrid Composite:-
In a hybrid composite usually there are two or more fibers which are different from one another in a single matrix phase. The most commonly used hybrid composite is the one which contains polymeric resin as the matrix and both glass and carbon fibers as reinforcing phase.
‘ 1.3.2 On the basis of Reinforcement:-
‘ Particle reinforced composites:-
Particle reinforced composites are again divided into large particle composites and dispersion strengthened composites. In large particle composites the size of particles is larger than that of dispersion strengthened composites. If the bonding is good then the matrix movement can be restrained. Concrete and Reinforced Concrete are examples of large particle composites.
‘ Fiber reinforced composites
A fiber-reinforced composite (FRC) is a composite building material that consists of three components: (i) the fibers as the discontinuous or dispersed phase, (ii) the matrix as the continuous phase, and (iii) the fine inter phase region, also known as the interface.
Ex:- carbon fibers, boron fibers, E-glass fibers, SiC fibers, etc.
‘ 1.4 Advantages composite materials:-
‘ Higher strength-to-density ratio and stiffness-to-density ratios.
‘ Better fatigue resistance and lower creep rate.
‘ Better elevated temperature properties.
‘ Lower coefficients of thermal expansion.
‘ Better wear resistance and radiation resistance.
‘ Higher temperature capability with fire resistance.
‘ Higher transverse stiffness and strength.
‘ No moisture absorption and no outgassing.
‘ Higher electrical and thermal conductivities.
‘ Fabric ability of whisker and particulate-reinforced MMCs with conventional
‘ Metalworking equipment.
‘ 1.5 Disadvantages of composite material:-
‘ Limited service experience.
‘ Higher cost of some material systems
‘ Complex fabrication methods for fiber-reinforced systems
‘ Use of composites is more challenging, material properties are less predictable.
‘ 1.6 Applications of Composite Materials:-
‘ In Composite golf clubs, archery bows, fishing rods, racquets and skis are now established products.
‘ Automobile industries: For cost reduction, weight reduction and recyclability it is widely used.
‘ Architectural, bridge, cladding, column wrapping, enclosure, fencing, masts, pipes, roofing, seismic retrofitting, tanks, tower.
‘ In construction of air craft, Aircraft propellers, Helicopter Airframes, Helicopter rotor blades and Helicopter rotor hubs.
‘ Power transmission tower, distribution poles, cables, cross-arms composites materials are use. Composite reinforced aluminum conductor cables (CRAC) replace traditional steel.
‘ 1.7 Wear of material:-
Wear is commonly defined as the undesirable deterioration of a component by the removal of material from its surface. It occurs by displacement and detachment of particles from surface. The wear of material may be due to the friction of metals against each other, eroding effect of liquid and gaseous media, scratching of solid particles from the surface and other surface phenomena. In laboratory tests, wear are usually determined by weight loss in a material and wear resistance is characterized by the loss in weight per unit area per unit time. There are following principle types of wear as described below.
1.7.1 Abrasive wear: – It results when non metallic particles penetrate the metal surface and cause removal of metallic debris. Abrasive wear is a dominant failure mechanism of engineering components. The abrasive wear resistance in general increases with increase in hardness.
1.7.2 Adhesive wear or metal to metal wear: – This wear caused due to relatives sliding or rolling movement of two mating metallic surfaces. If contact pressure are high it cause to permanent plastic deformation of rubbing component.
1.7.3 Erosive wear: – Erosive wear occur as a result of relative movement between metal and liquid or gas.
1.7.4Corrosive wear: – The destruction of materials by the action of surrounding medium is called corrosion. Corrosive wear begins at the surface and gradually penetrates into the matrix.
1.7.5Fatigue wear: – The removal of particles by cyclic processes comes under the category of fatigue wear. This type of wear predominates in most practical machine component.
1.8 Factors affecting wear of metallic materials:-
The wear rate can be influenced by a number of factors as given below:-
‘ Physico chemical properties of materials, such as composition, microstructure, hardness, work hardening characteristics, corrosion resistance, wear strength, etc.
‘ Wear conditions such as contact areas, load applied, temperature, presence of lubricants, degree of lubrication, rotational/sliding speed, flow rate of liquid or gas, nature of environment, duration of wear etc.
‘ Characteristics of abrasive involving hardness, shape and size.
‘ Design properties involving transmission of load, type of motion, test geometry etc.
1.9 Mechanical properties:-
Strength, hardness, toughness, elasticity, plasticity, brittleness, and ductility and
malleability are mechanical properties used as measurements of how metals behave under a load. These properties are described in terms of the types of force or stress that the metal must withstand and how these are resisted.
1.9.1 Strength:-
Strength is the property that enables a metal to resist deformation under load. The ultimate strength is the maximum strain a material can withstand. Tensile strength is a measurement of the resistance to being pulled apart when placed in a tension load.
Fatigue strength is the ability of material to resist various kinds of rapidly changing stresses and is expressed by the magnitude of alternating stress for a specified number of cycles.
Impact strength is the ability of a metal to resist suddenly applied loads.
1.9.2 Hardness:-
Hardness is the property of a material to resist permanent indentation. Because there are several methods of measuring hardness, the hardness of a material is always specified in terms of the particular test that was used to measure this property. Rockwell, Vickers, or Brinell are some of the methods of testing. Of these tests, Rockwell is the one most frequently used. The basic principle used in the Rockwell testis that a hard material can penetrate a softer one. We then measure the amount of penetration and compare it to a scale. For ferrous metals, which are usually harder than nonferrous metals, a diamond tip is used.
1.9.3 Toughness:-
Toughness is the property that enables a material to withstand shock and to be deformed without rupturing. Toughness may be considered as a combination of
strength and plasticity.
1.9.4 Elasticity:-
When a material has a load applied to it, the load causes the material to deform. Elasticity is the ability of a material to return to its original shape after the load is removed. Theoretically, the elastic limit of a material is the limit to which a material can be loaded and still recover its original shape after the load is removed.
1.9.5 Plasticity:-
Plasticity is the ability of a material to deform permanently without breaking or rupturing. This property is the opposite of strength. By careful alloying of metals, the combination of plasticity and strength is used to manufacture large structural members. For example, should a member of a bridge structure become overloaded, plasticity allows the overloaded member to flow allowing the distribution of the load to other parts of the bridge structure
1.9.6 Brittleness:-
Brittleness is the opposite of the property of plasticity. A brittle metal is one that breaks or shatters before it deforms. White cast iron and glass are good examples of brittle material. Generally, brittle metals are high in compressive strength but low in tensile strength. As an example, you would not choose cast iron for fabricating support beams in
a bridge
1.9.7 Ductility and malleability:-
Ductility is the property that enables a material to stretch, bend, or twist without cracking or breaking. This property makes it possible for a material to be drawn out into a thin wire. In comparison, malleability is the property that enables a material to deform by compressive forces without developing defects. A
malleable material is one that can be stamped, hammered, forged, pressed, or rolled into thin sheets.
1.10 Objectives of the present work:-
In this project we are going to study wear property and other mechanical property of carbide tool and HSS tool and study about who is batter one of them.
‘ 1.10.1 Tungsten Carbide tool:-
‘ Carbide tool inserts principally consist of tungsten carbide particles held together by cobalt or nickel as binder.
‘ Straight tungsten carbide tools contain about 94 percent tungsten carbide and 6 percent cobalt are used for machining cast iron and most other material.
‘ Carbide tools are made by powder metallurgy techniques.
‘ Tungsten carbide is approximately two times stiffer than steel.
‘ Tungsten carbide can be prepared by reaction of tungsten metal and carbon at 1400’2000 ??C.
‘ 1.10.2 High-speed steel (HSS):-
‘ High speed steel named because they could cut at speeds higher than those for carbon steels. The name is misleading because the speeds at which these material cuts are actually much lower than those used for many other material like carbide and other tools that are now available.
‘ HSS tool have excellent hard ability and can retain their hardness up to 650 c.
‘ They are relatively tough and moderately priced. They can be shaped easily.
‘ As such high speed steels are commonly used for drills, reamers; count bores, milling cutters and single point tools.
‘ One of the oldest and most common variety of HSS tool is 18:4:1.it contains 18 percent tungsten,4 percent chromium. 1 percent vanadium and
about 0.5 to 0.75 percent carbons. It is considered to be one of the best all purpose tool steels.
‘ Cobalt is sometimes added to high speed steels to improve their red hardness.
‘ HSS have one of major disadvantages in that they require lot of care in heat treatment. Rather complex heat treatment cycles are used to devlop the most favorable properties.
CHAPTER 2
LITERATURE REVIEW
ZHENG Guangming, ZHAO Jun, GAO Zhongjun, ZHOU Yonghui et al [1] studied the Cutting performance of Sialon-Si3N4 graded nano-composite ceramic cutting tools and reported that Tool life of the graded ceramic tool was higher than that of the common tool. The longer tool life of the graded nano-composite ceramic tool was attributed to its synergistic strengthening and toughening mechanisms induced by the optimum graded compositional structure of the tool and the addition of nano-sized particles. Wear mechanisms identified in the machining tests involve adhesive wear and abrasive wear. The mechanisms responsible for the higher tool life were determined to be the formation of compressive residual stress in the surface layer of the graded tools, which led to an increase in resistance to fracture.
METIN KOK et al [2] studied the Machinability of Al2O3 particle reinforced aluminium alloy composite and reported that the tool life of the TiN coated K10 tool was significantly longer than that of the HX tool. However, in
the machining of the matrix alloy the tool life difference between cutting tools was larger than that in the machining of the composite. The tool life decreased with an increase in the cutting speed for both tools in all cutting conditions.It is observed that the major tool wear forms were the combination of flank wear and rounding of the nose. For the K10 tools, removal of coated layer from the substrate material and BUE formation appeared when machining composites at lower cutting speed. For the HX tools, however, edge chipping and nose rounding was evident due to high temperature and stresses at the cutting edge.It was shown that cutting speed was the influential machining parameter on the tool wear. The tool wear increased considerably with increasing cutting speed.
For cutting tools, the TiN coated K10 cutting tool showed better performance than that of HX tool. The coating decreased tool wear and produced a
smoother surface finish. The surface roughness of the work piece was mostly affected by cutting speed. The optimum surface roughness in the machining of MMCs was obtained at a cutting speed of 160 m min-1 for K10 tool while the maximum surface roughness values appeared in the machining of the aluminium matrix alloy at the cutting speed of 100 m min-1 for HX tool. For the matrix alloy, the surface roughness values of both cutting tools decreased with increasing the cutting speed. For the composite, surface roughness values for the HX tool increased while those of K10 tool decreased a little up to 160 m min-1 cutting speed and thereafter increased sharply, with increasing the cutting speed.
Ewald Badisch, Horst Winkelmann and Friedrich Franek et al [3] studied the Wear resistance generally decreases under combined impact/abrasion with an increases of the testing temperature in CIAT. Softening effects, which become dominant at higher temperatures, increase the formation of mechanically mixed layers. Cold deformation and massive grooving are dominating effects in single phase austenitic microstructures. At higher temperatures a pronounced formation of MML takes place, which protects the material against wear. Breaking of coarse hard phases at high temperatures takes place in the Fe-Cr-C-B complex alloy due to fatigue effects and insufficient mechanical support by the matrix.
James N. Boland and Xing S. Li et al [4] studied the Micro structural Characterisation and Wear Behaviour of Diamond Composite Materials and reported that the wear behaviour of commercially produced diamond composite tools is highly variable. Since one of the major operational areas for diamond composites is in cutting, drilling and sawing for the mining, exploration and civil construction industries, there is a need for a simple and cost effective abrasive wear test for these super hard tool materials. As a first assessment procedure, an appropriate wear test of the type developed at CSIRO is recommended. In order to determine the source of any poor wear performance of diamond composite materials, it is also essential to study their
micro structural development. It has been shown in this review that optical microscopy, scanning electron microscopy and X-ray microscopy provide important data for assessing the homogeneity and phase integrity of diamond composites. Based on these observations, there is clearly a need to improve the quality of TSDC and PCD coated WC cutting elements by better quality control of the reactive sintering process.
Bhupesh Goyal,Alpesh Makwana, Akash Pandey et al [5] studied the Tool Wear Analysis of USM for Composite Material using Taguchi Technique and reported that All the factors investigated have been found to be significant for their effect on tool wear rate. However, amplitude has emerged as the most significant factor, followed by thickness of the work material. Work material and pressure have been found to be significant as far as TWR is concerned. The optimized process setting for achieving the optimal value of TWR has been identified. The confirmatory experiments conducted by using the optimized setting verified the validity of the optimized results. The optimal value of TWR was established as 53mg/min, as experimentally verified.
P. Sathia prathap, V. S. K. Vengatachalapathy, K. Palaniradja et al [6] studied the Machining of Hybrid Metal Matrix Composites and its Further Improvement-A Review and reported that it is noticed that there is essential need to select proper machining process for effective machining of hybrid Al/SiC/B4C-MMC. From the published research work it is clear that Al/SiC-MMC machining is one of the major problem, which resist its wide spread application in industry. CNC milling machine can help to obtain the desire result.
T. Prater, A.M. Strauss, G.E. Cook, C. Machemehl, P. Sutton and C. Cox et al [7] studied the statistical modelling and prediction of wear in friction stir welding of a metal matrix composite (Al 359/sic/20p) and reported that Tool wear in the Friction Stir Welding of the Metal Matrix Composite Al 359/SiC/20p was characterized for various process parameters using a Taguchi L27 orthogonal array. Three factors (rotation speed, traverse rate,
and length of weld) were correlated with a single outcome variable, percent tool wear. The multiple regression model (W=0.584 ‘ 1.038?? + 0.009w ‘ 6.028 with an R2 value of 0.81) indicates that Wear is strongly dependent on process parameters. This relationship is of the W’?l/v form where wear W, is inversely proportional to traverse rate, ??, and directly proportional to rotation speed, ??, and length of weld, l. The wear measurements are additionally dependent on the contrast capabilities of the camera and the lighting, which clearly delineate the boundary between the edge of the probe and the grid background. The definition of this boundary is of critical importance for the
subsequent area calculations. Although photographic methods have some limitations, they tend to be more accurate than mechanical gauging methods.
H.J. Liua,, J.C. Feng, H. Fujii, K. Nogi et al [8] studied the Wear characteristics of a WC’Co tool in friction stir welding of AC4AC30 vol%SiCp composite and reported that an appreciable tool wear is observed in the FSW of
AC4AC30 vol%SiCp AMC although the threaded tool is made of WC’Co hard alloy. The shoulder size and pin length are changed slightly, and the radial wear of the pin is most severe for the whole tool. The radial wear of the pin is very different at different locations of the pin, and the maximum wear is finally produced at a location of about one-third pin length from the pin root. The welding speed has a decisive effect on radial wear rate of the pin. The lower the welding speed, the higher the wear rate, and the maximum wear rate is produced in the initial welding.
Saroj K. Patel, Mithilesh Kumar et al [9] studied the Erosive Wear Characteristics of Carburized and Tempered Mild Steel Samples in Plain Soil’Water Slurry for Application in Agro’Industries and reported that Hardening effect immediately after carburization gave much higher hardness (60 ‘ 66 RC) and erosive wear resistance ( in soil-water slurry ) in the resultant carburized mild steel samples, and these results appear to be definitely superior than those obtained by conventional carburization. Erosive
wear resistance, in general, increased with increasing rotation (erosion) time in plain soil-water slurry irrespective of carburization and tempering conditions. Both the severe and mild wear losses were operative in the present study. With increasing tempering temperature up to 2500C, the hardness declined but the erosive wear resistance improved. From the point of view of commercial utilization, the carburization treatment involving 9300C, 2 hours, water quenching and tempering at 2000C appear most promising.
Donald H. Buckley et al [10] studied the effect of carbon content on friction and wear of cast irons and reported that Gray cast irons have lower friction and wear characteristics than do white cast irons. Increases in carbon content in gray cast irons produce more marked reductions in wear than do the same carbon increases in white cast iron. A linear wear track width relationship with load exists with gray cast iron. The friction behaviour of gray cast iron is sensitive to humidity. The changes in the friction and wear behaviour of cast irons and wrought steels .There exists an optimum for minimum in friction at 50 percent relative humidity with increased carbon content do not appear to be related to hardness.
Eugene L. Helton, Peoria; Preston L.Gale, et al [11] studied the composite wear-resistant alloy, and tools from same and reported that Spherical particles of wear-resistant alloy comprising boron, chromium and iron having maximum hardness for a given composition are produced by the rapid cooling of a molten alloy mixture. The resultant solid particles are then incorporated into a composite alloy wherein the solid particles are held together with a matrix of different material from the alloy. Inserts of the composite wear-resistant alloy are useful in producing long wearing tools
Manoj Singla, Lakhvir Singh, Vikas Chawla et al [12] studied the Wear Properties of Al-SiC Composites and reported that For a given load, the cumulative wear volumes of composites and pure aluminium pins increase linearly with sliding distance under dry sliding. The wear rate increases linearly with the increase in normal load. However, the
composites have shown a lower rate of wear (up to 20% SiC) as compared to that observed in pure aluminium. The average coefficient of friction decreases with increasing load in both pure aluminium and composites. However, the composites show a lower coefficient of friction than that observed in pure aluminium.
CHAPTER 3
EXPERIMETAL DETAILS
REFERENCES
[1]. ZHENG Guangming, ZHAO Jun, GAO Zhongjun, ZHOU Yonghui, Cutting performance of Sialon-Si3N4 graded nano-composite ceramic cutting tools, Inconel 718.
[2]. METIN KOK , a study on the machinability of al2o3 particle reinforced aluminium alloy composite,pp 272-281.
[3]. Ewald Badisch, Horst Winkelmann and Friedrich Franek, High-temperature cyclic impact abrasion testing:wear behaviour of single and multiphase materials up to 750 ??C, pp 359’366.
[4]. James N. Boland and Xing S. Li, Microstructural Characterisation and Wear Behaviour of Diamond Composite Materials, pp 1390-1419.
[5]. Bhupesh Goyal,Alpesh Makwana, Akash Pandey, Tool Wear Analysis of USM for Composite Material using Taguchi Technique, pp 1116-1120.
[6]. P. Sathia prathap, V. S. K. Vengatachalapathy, K. Palaniradja, Machining of Hybrid Metal Matrix Composites and its Further Improvement-A Review, pp 11-15.
[7]. T. Prater, A.M. Strauss, G.E. Cook, C. Machemehl, P. Sutton and C. Cox, statistical modelling and prediction of wear in friction stir welding of a metal matrix composite (Al 359/sic/20p), pp 1-13.
[8]. H.J. Liu, J.C. Feng, H. Fujii, K. Nogi, Wear characteristics of a WC’Co tool in friction stir welding of AC4AC30 vol%SiCp composite, pp 1635’1639.
[9]. Saroj K. Patel, Mithilesh Kumar, Erosive Wear Characteristics of Carburized and Tempered Mild Steel Samples in Plain Soil’Water Slurry for Application in Agro’Industries.
[10]. Donald H. Buckley, effect of carbon content on friction and wear of cast irons.
[11]. Eugene L. Helton, Peoria; Preston L.Gale, composite wear-resistant alloy,and tools from same.
[12]. Manoj Singla, Lakhvir Singh, Vikas Chawla, Study of Wear Properties of Al-SiC Composites, pp.813-819, 2009.