Analysis of Surface Integrity of Al/SiC Metal Matrix Composites
Analysis of Surface Integrity of Al/SiC Metal Matrix Composites
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Synopsis:
Synopsis:
Designed and fabricated aluminum-silicon carbide (Al/SiCp) metal matrix composites using stir casting, followed by an in-depth investigation into the influence of machining parameters on material response. Used Taguchi L9 orthogonal arrays for process optimization, assessed mechanical and thermal performance experimentally, and validated results through finite element modeling using Abaqus software.
 Highlighted Skills & Contributions
Materials Fabrication: Used stir casting to fabricate Al2024/SiCp MMCs with 3%, 5%, and 7% SiC weight fractions at mesh sizes 220 and 600.
Experimental Design: Employed Taguchi L9 orthogonal array to optimize cutting speed, feed, depth of cut, and preheating temperature.
Machining Analysis: Evaluated cutting forces, flank wear, and surface roughness under both room and elevated temperatures.
Finite Element Simulation (FEA): Modeled hot machining processes in Abaqus, simulating stress, tool wear, and heat distribution.
CAD & Mesh Modeling: Designed meshed workpiece and tool geometries for precise simulations using tetrahedral elements.
Micromechanical Testing: Conducted tensile, impact, and microhardness testing following ASTM standards.
Tool Material Engineering: Selected and analyzed performance of Sandvik PVD-coated carbide inserts for dry cutting applications.
Data Analysis & Optimization: Used signal-to-noise ratios for multi-objective optimization of machining parameters based on surface roughness and flank wear.
Key Achievements and Deliverables
Visualison on Abaqus CAE
STRESS vs TIME PLOT ON ABAQUS
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