Statistical Modeling of the Machinability of an In-Situ Synthesized RZ5/TiB2 Magnesium Matrix Composite in Dry Turning Condition

Machinability analyses of metal matrix composites are essential for manufacturing industries. The current study is focused on the mathematical modeling of the machinability of an in-situ synthesized RZ5-8 wt.% TiB2 composite using the Taguchi design statistical tools and analysis of variance (ANOVA). Taguchi’s method indicates that the feed rate is the most influential parameter, followed by the depth of cut and cutting speed in determining the cutting force and surface roughness during the machining of the RZ5/8 wt.% TiB2 composite. A regression analysis of the experimental data was carried out using ANOVA, and regression equations were established to estimate cutting force and surface roughness under different parametric conditions. The regression model was validated for other test conditions and the maximum deviation observed was ±10%. Main effects plots and response surface plots were developed to analyze the machining parameters’ individual and combined effects on the RZ5/8 wt.% TiB2 composite’s machinability. The chip morphology and tool wear of the RZ5/8 wt.% TiB2 composite were analyzed using FESEM under different machining conditions

Statistical Modeling of the Machinability of an In-Situ Synthesized RZ5/TiB₂ Magnesium Matrix Composite in Dry Turning Condition

Machinability analyses of metal matrix composites are essential for manufacturing industries. The current study is focused on the mathematical modeling of the machinability of an in-situ synthesized RZ5-8 wt.% TiB2 composite using the Taguchi design statistical tools and analysis of variance (ANOVA). Taguchi’s method indicates that the feed rate is the most influential parameter, followed by the depth of cut and cutting speed in determining the cutting force and surface roughness during the machining of the RZ5/8 wt.% TiB2 composite. A regression analysis of the experimental data was carried out using ANOVA, and regression equations were established to estimate cutting force and surface roughness under different parametric conditions. The regression model was validated for other test conditions and the maximum deviation observed was ±10%. Main effects plots and response surface plots were developed to analyze the machining parameters’ individual and combined effects on the RZ5/8 wt.% TiB2 composite’s machinability. The chip morphology and tool wear of the RZ5/8 wt.% TiB2 composite were analyzed using FESEM under different machining conditions

Influence of Si3N4 on the Dry Sliding Wear Characteristics of Stir-Cast Cu-10Sn/xSi3N4 Metal Matrix Composite for Bearing Applications

Bronze metal matrix composites (MMCs) are futuristic materials that may find applications in automobile, aviation, and marine industries, specifically for propellers in submarines, bearings, and bushings for defence purposes. The present investigation studied the effect of Si3N4 (5, 10, 15 wt%) ceramic particles on the physical, metallurgical, and tribological behaviour of Cu-10Sn/Si3N4 MMCs. Cast rods of three composites and a base alloy were fabricated using the liquid metallurgy route. The microstructural characterisation for the cast samples was conducted using FESEM (Field Emission Scanning Electron Microscope), EDS (Energy Dispersive Spectroscopy), XRD (X-ray diffraction), and TEM (Transmission Electron Microscope), which revealed that the Cu-10Sn alloy reinforced with 5 wt% of Si3N4 had homogeneous distribution and perfect bonding of the Si3N4 with the bronze MMC. The dry sliding wear test was performed by varying parameters such as the applied load (10, 20, 30 N) and sliding velocity (1, 2, 3 m/s). The specific wear rate (SWR) increased against an increased load. However, the SWR and coefficient of friction decreased and then increased against an increasing sliding velocity due to tribolayer formation. The primary wear mechanism observed at low and high loads was severe delamination. In contrast, the wear mechanism was adhesion wear at high and low velocities. Amongst the researched samples, Cu-10Sn/5 wt% Si3N4 composites revealed the least SWR at a load of 10 N and sliding velocity of 2 m/s and hence can be recommended for manufacturing bearings and bushings in the automobile and defence industry

Influence of Si₃N₄ on the Dry Sliding Wear Characteristics of Stir-Cast Cu-10Sn/xSi₃N₄ Metal Matrix Composite for Bearing Applications

Bronze metal matrix composites (MMCs) are futuristic materials that may find applications in automobile, aviation, and marine industries, specifically for propellers in submarines, bearings, and bushings for defence purposes. The present investigation studied the effect of Si3N4 (5, 10, 15 wt%) ceramic particles on the physical, metallurgical, and tribological behaviour of Cu-10Sn/Si3N4 MMCs. Cast rods of three composites and a base alloy were fabricated using the liquid metallurgy route. The microstructural characterisation for the cast samples was conducted using FESEM (Field Emission Scanning Electron Microscope), EDS (Energy Dispersive Spectroscopy), XRD (X-ray diffraction), and TEM (Transmission Electron Microscope), which revealed that the Cu-10Sn alloy reinforced with 5 wt% of Si3N4 had homogeneous distribution and perfect bonding of the Si3N4 with the bronze MMC. The dry sliding wear test was performed by varying parameters such as the applied load (10, 20, 30 N) and sliding velocity (1, 2, 3 m/s). The specific wear rate (SWR) increased against an increased load. However, the SWR and coefficient of friction decreased and then increased against an increasing sliding velocity due to tribolayer formation. The primary wear mechanism observed at low and high loads was severe delamination. In contrast, the wear mechanism was adhesion wear at high and low velocities. Amongst the researched samples, Cu-10Sn/5 wt% Si3N4 composites revealed the least SWR at a load of 10 N and sliding velocity of 2 m/s and hence can be recommended for manufacturing bearings and bushings in the automobile and defence industry