Characterizing the tool wear morphologies and life in milling A520-10%SiC under various lubrication and cutting conditions | Scientific Reports

Scientific Reports volume 14, Article number: 26870 (2024) Cite this article Metrics details Metal matrix composites (MMCs) are lightweight and widely used materials constantly applied in various

Scientific Reports volume 14, Article number: 26870 (2024) Cite this article

Metrics details

Metal matrix composites (MMCs) are lightweight and widely used materials constantly applied in various industries. Such material’s structural and functional properties change under the contributions of various reinforcing particles and base materials. Multiple technologies are used in the manufacturing and machining these materials, and numerous studies are oriented toward this domain through academic and industrial projects. One aspect that receives less attention is understanding the combined effects of cutting parameters, lubrication conditions, and reinforcing elements on the machinability of such materials. Amongst MMC, limited attention has been paid to A520 alloys reinforced with SiC particles. Therefore, this work investigated the tool wear size and morphology in milling A520-10%SiC under various lubrication and cutting conditions. It was observed that cutting conditions significantly affect the tool life and wear morphology when machining A520-10%SiC. The main wear modes observed were abrasion and adhesion, mainly presented as the built-up edge (BUE) and Built-up layer (BUL). The wet method reduced the formation of BUE and BUL by 95% and MQL by 60% compared to the dry method. It was also observed that better tool life was observed under wet mode than readings made under MQL and dry modes. The outcomes could generate a practical window for the optimum selection of cutting parameters when machining reinforced Al-MMCs, in principle, A520-10%SiC.

The utilization of metal matrix composites (MMCs) has been progressively rising across several manufacturing sectors, encompassing the production of engine components, drive shafts, braking mechanisms, pump casings, and supercharger units. MMC’s ability to modify its properties by combining different matrix alloys and additives sets it apart from other industrial metals. These reinforcements include particles, short fibers, whiskers, continuous fibers, and monofilaments. Using materials with suitable mechanical properties is one of the most essential industrial interests. However, it is usually not possible to maintain all mechanical properties simultaneously. For instance, increasing strength, weight, and decreased flexibility may be two unpleasant factors in product design. The 5000 series aluminum has magnesium alloy elements. Due to its good corrosion resistance and high strength at low temperatures, AlMg is generally used in ship fabrication, chemical apparatus and pipelines, refrigeration technology, and automobiles. Excellent weldability is crucial for use in aircraft construction, and there are also additions of scandium and zirconium for better weldability1.

A notable type of MMC is the aluminum-alloy matrix composite (AlMMC), which incorporates ceramic reinforcements like silicon carbide (SiC)2,3. Exceptional characteristics of MMCs comprise elevated strength-to-weight proportions, rigidity, hardness, resistance to corrosion and wear, and minimal thermal expansion have made it a widely used material in various fields, especially in the automotive and aerospace industries. Aluminum-based metal matrix composites reinforced with different additives have become preferred due to their high wear resistance, low thermal expansion, lightweight, and improved mechanical properties. Therefore, numerous research studies focused on increasing strength while maintaining or reducing weight and improving flexibility4,5,6,7,8,9,10. Although the production of composites has successfully enhanced the mechanical properties, in principle, the strength-to-weight ratio of machining reinforced MMCs is still associated with many hindering problems. Numerous investigations were completed to solve or improve these problems11,12,13,14. Emine Şap et al. showed that the particle additive ratio was the most critical parameter affecting surface roughness, tool wear, and cutting temperature. In addition, it was observed that chip types and wear types changed according to increasing reinforcement rates15.

Reinforcing particles in such composites are abrasive and usually have high hardness, which may generate severe damage and failures to the cutting tools and surface quality attributes16. It was shown that 5% additive (2% B, 3% CrC) provides improved properties such as surface roughness, tool wear, and cutting temperature17. Several studies assessed the performance of multiple cutting tools in machining MMCs13,18. Different types of tools were evaluated when used in machining MMCs19,20,21. Chaudhari investigated the interaction effects of cutting tools during machining MMCs and emphasized the importance of cutting conditions and the type and size of the cutting tools used22. The use of cutting fluid and surface texture on the cutting tool’s life and wear is another interesting scientific topic that has received particular attention in the past few years23,24,25,26. For instance, Karim noticed that using surface texture on the cutting tool may improve the cutting tool’s life and reduce the incidence of tool wear27. One study proposes a highly condition-adaptive method for tool wear state monitoring and remaining useful life (RUL) estimation under time-varying operation conditions28. Research in creating texture on tools shows that the texture’s depth and shape significantly affect the machining performance and that its combination with dry lubricant improves the lubrication performance23. Gururaja et al.29 studied tool life, tool wear, machining, and chip formation during MMC machining. Cutting fluid reduces the cutting area’s temperature, friction, and lubrication. Despite these advantages, the presence of liquid causes pollution of the environment, damage to the operator, and an increase in production costs30. Researchers have investigated various methods to reduce or eliminate fluid use to overcome the above challenges. Machining with the MQL method using vegetable oils is one of the ways that researchers are trying to replace traditional cooling methods31. MQL is a mixture of compressed air and a small amount of oil in very fine droplets that form a pulverized spray on the cutting area in 10–150 ml/h32. MQL penetrates the cutting zone in high-speed milling and performs three tasks: cooling the tool and workpiece, lubricating, and effective chip removal.

MQL significantly affects the cutting temperature over a wide range of speeds and reduces the cutting tool wear rate compared to completely dry machining33. According to the conducted research studies, the efficiency of MQL method needs more studies, and it is necessary to compare this method in equal conditions with other common methods. Umesh et al.34 have optimized turning in three modes: dry, wet, and MQL. The study indicated that the feed rate had a pronounced impact on surface roughness (Ra) and cutting force (Fc) across various machining scenarios. Optimal results for Ra were achieved with dry machining, while MQL was most effective in diminishing Fc, courtesy of its cooling and lubricative attributes. A 0.03 mm/rev feed rate emerged as the most advantageous across all machining contexts, contributing to reduced Ra and Fc. On the other hand, MQL provided the best tool wear index and surface characteristics, i.e., surface roughness and surface topography, which is related to spectacular ability in developing the friction conditions in the deformation zones35. Additionally, wet machining was instrumental in achieving lower Ra values, thanks to its capacity for efficient chip removal and cleansing of the cut area.

Conversely, employing MQL reduced cutting forces by 17% and 50% relative to dry and wet machining under ideal conditions. Moreover, a 33% and 3% enhancement in surface roughness was observed in dry mode as opposed to wet and MQL modes. While continuous research efforts are directed toward enhancing the machining processes for MMCs, numerous challenges and questions remain unanswered or insufficiently appealing for scholarly inquiry. Existing studies have indicated that the properties and outcomes of machining MMCs differ from those encountered when processing traditional materials. Consequently, it is critical to examine the impact of cutting parameters on the machinability of MMCs, with particular emphasis on tool wear, the size and morphology of wear under various cutting conditions, reinforcing elements, and lubrication strategies.

In academic exploration, there is a notable scarcity of focus on evaluating the machining and machinability of novel MMC varieties, especially under various lubrication modes, which is essential to bridge the existing knowledge gap. Specifically, among MMCs, the A520 alloy reinforced with SiC particles has not received sufficient academic attention, and limited works have been reported in this context. This study aims to evaluate the machinability of A520 + 10%SiC under different cutting conditions and three lubrication modes: dry, MQL, and wet. Primary machinability characteristics of interest include surface roughness, flank wear in size and morphology, and cutting forces. The findings are expected to contribute to establishing a practical guideline for optimizing cutting parameters when machining AlMMCs, particularly A520 + 10%SiC.

The cubic blocks of A520 with a volume fraction of 10% of SiC particles with a diameter of 40 μm, scientifically presented as A520-10%SiC, were used as the work part of this work. The quantometry of the tested parts is presented in Table 1. To fabricate reinforced Al-MMC, the SiC particles, with an average diameter of 40µm, underwent heat treatment at 1000 °C or 2 h to facilitate the breaking of the aggregates and prevent them from sticking together. The aluminium alloy was also used as the base or matrix of the composite. In the next step, SiC particles were preheated at 400 °C for 60 min, improving wettability. The casting operation used an induction furnace, as shown in Fig. 1. In the first step, 90% of the aluminium alloy volume was placed in the plant. After the complete alloy melting, the SiC particles were added gradually to the mixture at 750 °C. SF6 shielding gas was injected into the mixture from the beginning to the stirring stage to prevent oxidation formation. A steel stirrer with the following details was used to stir the melt: 28.6 cm long and four blades with length and width of 2 cm and 1 cm, respectively, and an angle of 30º to the direction of the stirrer handle. The stirrer was covered with zircon slurry to prevent interactions with the melt. Before the melt was poured into the mold, it was preheated to avoid any possible sticks between the mold and the melt. After the stirring time was completed, the stirrer was removed from the melt, and the melt was poured into the mold. The main stages of composite fabrication using a casting system are shown in Fig. 2.

Schematic of the furnace.

The stages of the casting process.

The end milling operation was performed with a 3-axis CNC machine tool (Power: 50kW, Speed: 28,000 rpm; torque: 50 Nm) under different lubrication conditions: dry, MQL, and wet (Fig. 3). As shown in Table 2, the cutting speed was used at three levels of 120, 180, and 240 m /min, while a fixed value of depth of cut (1 mm) and feed rate (0.1 mm/tooth) were used. The Iscar-coated carbide insert was used in the tests (Table 3). Each cutting test was performed in three passes, which led to 33cm of total length of cut (Fig. 4). The bio-lubricant MecGreen was also used in the MQL and wet tests. The flow rates were 150 ml/hr and 5l/hr for wet and MQL modes, respectively. The milling operation is done with a holder with a diameter of 10 mm and two teeth (two inserts), according to climb milling. The machining range is in wet mode with four nozzles separated by a proper distance and angle, and in MQL mode, one nozzle performs the spraying operation.

The experimental set-up.

The dimensions of the tested work parts (unit is mm).

As shown in Fig. 5, the abrasion can be seen in all three cutting speeds. The leading cause of this wear mode is the direct contact of the SiC ceramic particles with the tool’s coating layer, which may lead to rapid coating removal. Another important phenomenon in dry milling is the presence of an accumulated edge on the side surface and the cutting tool, known as a built-up edge (BUE). The BUE can be seen in all three cutting speeds. The leading cause of this phenomenon is the presence of aluminum, which is the primary material of the composite, and it has been transferred and located on the top of the cutting tool, generating a new edge covered by aluminum. Since aluminum is a soft and flexible metal, it can be inferred that this softness increases due to elevated temperature in the machining area, and the friction between the aluminum and the cutting tool strengthens. Therefore, BUE and BUL appear in some areas23. Increasing the cutting speed from 120 to 180 m/min shows no noticeable change in the BUE. However, at 240 m/min, increased BUE can be observed. This trend can be explained by the fact that the applied cutting speed (240m/min) is probably near the critical permitted cutting speed, increasing the incidence of BUE. It can be inferred that dry milling at such a cutting speed is not recommended.

SEM image of the chip surface of the cutting tool in the dry mode.

The EDS and map analysis at 240 m/min speed (Fig. 6) exhibit the presence of a high percentage of aluminium, magnesium, and a lower amount of titanium, which is the material of the coating layer. The map analysis of the tool’s surface shows that the amount of aluminium and magnesium, which are the main elements and the most significant weight percentage of the composite, as well as the carbon element, which is the element that forms the reinforcement particles, are mainly seen on the cutting edge that other locations. On the other hand, the amount of titanium, which is the main element of the coating layer, has been dramatically reduced in the area where abrasion occurred. The flank of the tool in a dry milling state (Fig. 7) exhibits that BUL and abrasion can be seen at all cutting speeds. By increasing the speed from 120 to 180 m/min, the BUL has not changed widely. However, at a speed of 240 m/min, the thickness of the BUL increased due to the increase in temperature and friction.

SEM image and map analysis of cutting tool chip surface at a speed of 240 m/min in the dry mode.

SEM image of the flank surface of the cutting tool in the dry mode.

MQL machining was associated with a significant reduction in BUE in all three cutting speeds compared to observations made in dry mode (Figs. 8, 9). Cooling down the work part and the cutting zone is expected to decrease the friction and temperature in the cutting zone. The reduction of these two factors is needed for BUE formation, while less BUL was seen under the same condition. During wet machining, the particles stick to the tool’s surface, and due to the thermal shock resulting from the collision of the cutting fluid, a BUL is generated. Lower BUL and BUE were observed at higher levels of cutting speed. It could be inferred that BUL and BUE formations are associated with critical cutting speed levels, which vary according to lubrication, cutting conditions, and material properties. The EDS analysis (Fig. 8) shows a large percentage of tungsten, wear, and loss of the coating layer on the surface with a lighter color. Because tungsten is tool’s main element, its appearance indicates the destruction of the coating layer by abrasion phenomenon. However, it is noteworthy that the abrasion phenomenon did not change considerably compared to observations made under dry mode. One reason for this phenomenon is that cutting fluid has almost no effect on the amount and percentage of contact between the SiC reinforcing particles and the surface of the cutting tool, and as similar to observations made in dry mode, coating removal was observed. As shown in Fig. 9, the BUL area has increased and become thicker at higher cutting speeds. This could be due to thermal effects at higher cutting speeds, which could strengthen the adhesion phenomenon despite the use of lubrication in the entire process.

SEM image of rake face wear in MQL mode.

SEM image of the flank surface of the cutting tool in MQL mode.

SEM image of the rake surface of the cutting tool in wet mode.

According to Fig. 10, several facts are evident (Fig. 10). Firstly, it can be observed that despite the cutting speed used, the coating removal in the wet mode is very apparent. In other words, the cutting fluid in the cutting zone did not effectively control the wear, and it can be indicated as similar to other lubrication modes; the abrasion is the dominant wear mode even in wet mode, despite the level of cutting speed used. Metal is the contact and stretching of the reinforcement particles with the coating layer of the tool, which happens due to the high hardness of these particles, which are mainly ceramic. The cutting fluid does not help reduce this contact, and even by creating a thermal shock on these particles, it may cause the particles to work hard and become harder, accelerating the abrasion mechanism. Also, removing reinforcing SiC particles and combining them with cutting fluid can cause the formation of an abrasive slurry that accelerates wear when it hits the surface. Furthermore, according to Fig. 11, BUL and BUE were significantly reduced in all cutting speeds compared to the dry mode. In fact, by applying more cutting fluid on the surface of the cutting tool, a more significant temperature drop is created. This decrease in temperature, along with the improvement of lubrication, has caused a reduction in the friction coefficient. Even though the material of the base or the matrix of the composite workpiece is favorable for the formation of accumulated edges in machining, it prevents BUE formation. Therefore, less BUL was formed. At a cutting speed of 120 m/min, no BUE can be seen because the cutting fluid does not allow the formation and enlargement of the layer, and in fact, BUE was formed. Only a tiny amount of BUL with a very low thickness can be seen on the cutting tool surface at this speed. At 180 m/min speed, a minimal amount of Al-MMC can be seen sticking to the tool’s surface, and BUE was formed, while only a tiny BUL was created. At the speed of 240 m/min, because the cutting speed was higher, the temperature in the cutting area and the formation of chips increased and probably caused the formation of a small BUE.

SEM image of the flank wear modes under wet mode.

VB .vs cutting time under lubrication modes at (a) cutting speed 120 m/min; (b) cutting speed 180 m/min; (c) cutting speed 240 m/min.

To assess the tool life and wear progress due to various levels of cutting time and cutting speed, the flank wear size was recorded in each cutting pass according to established standards (Fig. 12a–c). Figure 12a illustrates that the wet lubrication method exhibited minimal wear across all three-time intervals, surpassing other lubrication approaches. This superior wear resistance is likely due to its adequate friction and heat reduction. Figure 12b shows that the wet mode performed better than other lubrication modes despite the cutting speeds used, and it could reduce the wear rate on the flank side of the cutting tool. Although the tool’s wear was lower than the dry mode in the first two cutting slots, no significant difference in wear size could be observed. Even at the final point, the amount of wear in the MQL mode exceeded the measurements under dry mode. In the diagram related to the cutting speed of 240 m/min (Fig. 12c), the amount of wear measured in the dry state and MQL were close. However, with increased cutting speed, the performance of the MQL method has improved, and the amount of wear has been lower than in the dry mode. At this speed, like the previous two cutting speeds, the lowest wear was observed under wet mode because the flow rate of the cutting fluid is higher than the MQL mode, and it has been more successful in reducing flank wear and increasing the life of the tool.

This research examined the wear morphologies of inserts used in machining Al520MMC, reinforced with 10% SiC particles. It explored how cutting conditions and cooling and lubrication approaches affect these wear morphologies and flank wear size. This study provides valuable insights into the morphology of tool flank wear when milling Al520MMC. The observations and results can be presented as follows:

Despite the type of lubrication used, higher cutting speeds increased tool wear, and dry machining led to more wear than wet and MQL modes. These trends can be attributed to the inevitable collisions between the cutting tooltip and the SiC particles, which are distributed heterogeneously throughout the base material.

The leading wear modes in almost all milling tests were abrasion, BUL, and BUE. BUE and BUL were observed in all cutting conditions and lubrication modes due to the presence of aluminum as a matrix.

The soft nature of Al520MMC also contributes to the occurrence of BUE under all lubrication modes and cutting speeds. Moreover, abrasions were seen on the flank faces due to the contact between the cutting tool and the SiC elements. Lower BUE was observed at lower cutting speeds, possibly due to lower temperature generation. However, improving the cooling conditions from dry to MQL and wet generated more BUE and less BUL.

MQL and wet modes have been unable to reduce the abrasion mechanism. The leading cause of this type of wear is the contact of SiC reinforcing particles with the coating layer of the tool, and the cutting fluid has not been effective in reducing the amount of this contact. Furthermore, in some cases, better performance was observed under dry mode than under MQL model. This phenomenon reflects the complexity and difficulty in predicting lubrication modes’ performance in machining reinforced MMCs.

Carbide tool coating is almost ineffective against the wear mechanism caused by contact with SiC reinforcing particles. In fact, despite the cutting conditions used, coating removal was observed.

To advance future research and findings, further studies should be undertaken to explore the application of quantitative imaging as a reliable, non-destructive method for quality control during the machining of MMCs. Additional areas that warrant attention include observing and examining the impact of different reinforcing elements and base materials on the emission of dust particles during the machining of MMCs. This presents a promising direction for academic exploration in this field. In addition, a subsequent article will exclusively address the signal processing of the measured cutting forces within the time, frequency, and wavelet domain.

Data sets generated during the current study are available from the corresponding author on reasonable request.

Metal matrix composite

Minimum quantity lubrication

Built-up layer

Built-up edge

Scanning electron microscope

Energy-dispersive X-ray spectroscopy

Maximum flank wear

Cutting speed

Feed rate

Feed per tooth

Axial depth of cut

Tungsten

Cobalt

Aluminium

Zinc

Iron

Manganese

Magnesium

Chrome

Titanium

Silicon

Silicon carbide

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Sustainable Manufacturing Systems Research Laboratory (SMSRL), School of Mechanical Engineering, Iran University of Science and Technology, Tehran, Iran

Masoud Saberi, Seyed Ali Niknam & Ramin Hashemi

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Validation, M.S.; formal analysis, M.S.; investigation, M.S., S.A.N; writing—original draft preparation, M.S., S.A.N., supervision and writing—review and editing, S.A.N., R.H. All authors have read and agreed to the published version of the manuscript. Msaoud Saberi: M.S Seyed Ali NIknam: S.A.N Ramin Hashemi: R.H

Correspondence to Seyed Ali Niknam.

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Saberi, M., Niknam, S.A. & Hashemi, R. Characterizing the tool wear morphologies and life in milling A520-10%SiC under various lubrication and cutting conditions. Sci Rep 14, 26870 (2024). https://doi.org/10.1038/s41598-024-77652-8

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Received: 17 July 2024

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DOI: https://doi.org/10.1038/s41598-024-77652-8

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