Finite Element Simulation Of Aluminium Silicon Carbide Metal Matrix Composite Machining

Aluminium Silicon Carbide is one of the metal matrix composite. Drilling and reaming of Al/SiC composites is very challenging. An overall process optimization strategy is very needed for the actual production. This must be based on a deep understanding of the cutting mechanism. Different drill geome...

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Main Author:	Ahmad Adli, Muhammad Akmal
Format:	Thesis
Language:	English English
Published:	2020
Subjects:	T Technology (General)
Online Access:	http://eprints.utem.edu.my/id/eprint/25431/1/Finite%20Element%20Simulation%20Of%20Aluminium%20Silicon%20Carbide%20Metal%20Matrix%20Composite%20Machining.pdf http://eprints.utem.edu.my/id/eprint/25431/2/Finite%20Element%20Simulation%20Of%20Aluminium%20Silicon%20Carbide%20Metal%20Matrix%20Composite%20Machining.pdf
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id	my-utem-ep.25431
record_format	uketd_dc
institution	Universiti Teknikal Malaysia Melaka
collection	UTeM Repository
language	English English
advisor	Raja Abdullah, Raja Izamshah
topic	T Technology (General) T Technology (General)
spellingShingle	T Technology (General) T Technology (General) Ahmad Adli, Muhammad Akmal Finite Element Simulation Of Aluminium Silicon Carbide Metal Matrix Composite Machining
description	Aluminium Silicon Carbide is one of the metal matrix composite. Drilling and reaming of Al/SiC composites is very challenging. An overall process optimization strategy is very needed for the actual production. This must be based on a deep understanding of the cutting mechanism. Different drill geometry may give different effect on the heat generation and thrust force on bone. Web thickness, point angle and helix angle are the drill geometry factors studied. So, modeling of Al/SiC drilling process by ANSYS to simulate the effect of axial thrust force and heat generation on bone in order to prevent thermal osteonecrosis. Finite element simulation is applied because the process variables are difficult to measure and directly measurable from the cutting process. There are 2 stages of methodology. During stage 1, the purpose is to validate the simulation whether the model valid or not by testing the simulation with available drill bit with straight shank. During stage 2, simulation is preceded with the drill geometry by using the validated model setting. Response surface methodology is used to design the experiment and ANOVA method is used to analysis the data. It was found that there is significant effect on temperature by the drill geometry involved, and not significant effect on thrust force. There are 10 optimized solutions suggested in this study. First solution (31.92% web thickness, 90° point angle, 31.32° helix angle) and second solution (32% web thickness, 90° point angle, 31.33° helix angle) are predicted as highly desirable for the study.
format	Thesis
qualification_name	Master of Philosophy (M.Phil.)
qualification_level	Master's degree
author	Ahmad Adli, Muhammad Akmal
author_facet	Ahmad Adli, Muhammad Akmal
author_sort	Ahmad Adli, Muhammad Akmal
title	Finite Element Simulation Of Aluminium Silicon Carbide Metal Matrix Composite Machining
title_short	Finite Element Simulation Of Aluminium Silicon Carbide Metal Matrix Composite Machining
title_full	Finite Element Simulation Of Aluminium Silicon Carbide Metal Matrix Composite Machining
title_fullStr	Finite Element Simulation Of Aluminium Silicon Carbide Metal Matrix Composite Machining
title_full_unstemmed	Finite Element Simulation Of Aluminium Silicon Carbide Metal Matrix Composite Machining
title_sort	finite element simulation of aluminium silicon carbide metal matrix composite machining
granting_institution	Universiti Teknikal Malaysia Melaka
granting_department	Faculty of Manufacturing Engineering
publishDate	2020
url	http://eprints.utem.edu.my/id/eprint/25431/1/Finite%20Element%20Simulation%20Of%20Aluminium%20Silicon%20Carbide%20Metal%20Matrix%20Composite%20Machining.pdf http://eprints.utem.edu.my/id/eprint/25431/2/Finite%20Element%20Simulation%20Of%20Aluminium%20Silicon%20Carbide%20Metal%20Matrix%20Composite%20Machining.pdf
_version_	1747834127107751936
spelling	my-utem-ep.254312021-12-12T22:55:23Z Finite Element Simulation Of Aluminium Silicon Carbide Metal Matrix Composite Machining 2020 Ahmad Adli, Muhammad Akmal T Technology (General) TA Engineering (General). Civil engineering (General) Aluminium Silicon Carbide is one of the metal matrix composite. Drilling and reaming of Al/SiC composites is very challenging. An overall process optimization strategy is very needed for the actual production. This must be based on a deep understanding of the cutting mechanism. Different drill geometry may give different effect on the heat generation and thrust force on bone. Web thickness, point angle and helix angle are the drill geometry factors studied. So, modeling of Al/SiC drilling process by ANSYS to simulate the effect of axial thrust force and heat generation on bone in order to prevent thermal osteonecrosis. Finite element simulation is applied because the process variables are difficult to measure and directly measurable from the cutting process. There are 2 stages of methodology. During stage 1, the purpose is to validate the simulation whether the model valid or not by testing the simulation with available drill bit with straight shank. During stage 2, simulation is preceded with the drill geometry by using the validated model setting. Response surface methodology is used to design the experiment and ANOVA method is used to analysis the data. It was found that there is significant effect on temperature by the drill geometry involved, and not significant effect on thrust force. There are 10 optimized solutions suggested in this study. First solution (31.92% web thickness, 90° point angle, 31.32° helix angle) and second solution (32% web thickness, 90° point angle, 31.33° helix angle) are predicted as highly desirable for the study. 2020 Thesis http://eprints.utem.edu.my/id/eprint/25431/ http://eprints.utem.edu.my/id/eprint/25431/1/Finite%20Element%20Simulation%20Of%20Aluminium%20Silicon%20Carbide%20Metal%20Matrix%20Composite%20Machining.pdf text en public http://eprints.utem.edu.my/id/eprint/25431/2/Finite%20Element%20Simulation%20Of%20Aluminium%20Silicon%20Carbide%20Metal%20Matrix%20Composite%20Machining.pdf text en validuser https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=119591 mphil masters Universiti Teknikal Malaysia Melaka Faculty of Manufacturing Engineering Raja Abdullah, Raja Izamshah 1. Fathipour, M., Zoghipour, P., Tarighi, J., & Yousefi, R. (2012). Investigation of Reinforced Sic Particles Percentage on Machining Force of Metal Matrix Composite. Modern Applied Science, 6. https://doi.org/10.5539/mas.v6n8p9 2. Iwata, K., Osakada, K., & Terasaka, Y. (1984). Process Modeling of Orthogonal Cutting by the Rigid-Plastic Finite Element Method. Journal of Engineering Materials and Technology, 106(2), 132–138. https://doi.org/10.1115/1.3225687 3. Li, Y., Cao, J., & Williams, C. (2019). Competing Failure Mechanisms in Metal Matrix Composites and Their Effects on Fracture Toughness. Materialia, 5, 100238. https://doi.org/10.1016/j.mtla.2019.100238 4. Livermore Software Technology Corporation. (n.d.). ANSYS/LS-DYNA. In ANSYS/LS-DYNA reference manual, Release 10. 7374 Las Positas Road, Livermore. 5. Long, S. G., & Zhou, Y. C. (2005). Thermal fatigue of particle reinforced metal-matrix composite induced by laser heating and mechanical load. Composites Science and Technology. https://doi.org/10.1016/j.compscitech.2004.12.009 6. Meijer, G., Ellyin, F., & Xia, Z. (2000). Aspects of residual thermal stress/strain in particle reinforced metal matrix composites. Composites Part B-Engineering - COMPOS PART B-ENG, 31, 29–37. https://doi.org/10.1016/S1359- 8368(99)00060-8 7. Monaghan, J., & Brazil, D. (1998). Modelling the flow processes of a particle reinforced metal matrix composite during machining. Composites Part A: Applied 8. Science and Manufacturing. https://doi.org/10.1016/s1359-835x(97)00047-x Ozben, T., Kilickap, E., & Çakir, O. (2008). Investigation of mechanical and machinability properties of SiC particle reinforced Al-MMC. Journal of Materials Processing Technology. https://doi.org/10.1016/j.jmatprotec.2007.06.082 9. Pramanik, A., Zhang, L., & Arsecularatne, J. (2007). Micro-Indentation of Metal Matrix Composite - An FEM Investigation. Key Engineering Materials - KEY ENG MAT, 340–341,563–570.https://doi.org/10.4028/www.scientific.net/KEM.340-341.563 10. Pramanik, A., Zhang, L. C., & Arsecularatne, J. A. (2006). Prediction of cutting forces in machining of metal matrix composites. International Journal of Machine Tools and Manufacture. https://doi.org/10.1016/j.ijmachtools.2005.11.012 11. Rajasekar, S., Pitchai, P. nathan, & Veerapadran, C. (2006). Research Methodology. 12. Reddy, P. R., & Sriramakrishna, A. A. (2002). Analysis of orthogonal cutting of aluminium-based composites. Defence Science Journal. https://doi.org/10.14429/dsj.52.2194 13. Singh, S., Singh, I., & Dvivedi, A. (2013). Multi objective optimization in drilling of Al6063/10% SiC metal matrix composite based on grey relational analysis. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 227(12), 1767–1776. https://doi.org/10.1177/0954405413494383 14. Strenkowski, J. S., Hsieh, C. C., & Shih, A. J. (2004). An analytical finite element technique for predicting thrust force and torque in drilling. International Journal of Machine Tools and Manufacture.https://doi.org/10.1016/j.ijmachtools.2004.01.005 15. Zhou, li, Huang, S., Wang, D., & Yu, X. (2011). Finite element and experimental studies of the cutting process of SiCp/Al composites with PCD tools. The International Journal of Advanced Manufacturing Technology, 52, 619–626. https://doi.org/10.1007/s00170-010-2776-2 16. Zhu, Y., & Kishawy, H. A. (2005). Influence of alumina particles on the mechanics of machining metal matrix composites. International Journal of Machine Tools and Manufacture. https://doi.org/10.1016/j.ijmachtools.2004.09.013 17. Fathipour, M., Zoghipour, P., Tarighi, J., & Yousefi, R. (2012). Investigation of Reinforced Sic Particles Percentage on Machining Force of Metal Matrix Composite. Modern Applied Science, 6. https://doi.org/10.5539/mas.v6n8p9 18. Iwata, K., Osakada, K., & Terasaka, Y. (1984). Process Modeling of Orthogonal Cutting by the Rigid-Plastic Finite Element Method. Journal of Engineering Materials and Technology, 106(2), 132–138. https://doi.org/10.1115/1.3225687 19. Li, Y., Cao, J., & Williams, C. (2019). Competing Failure Mechanisms in Metal Matrix Composites and Their Effects on Fracture Toughness. Materialia, 5, 100238. https://doi.org/10.1016/j.mtla.2019.100238 20. Livermore Software Technology Corporation. (n.d.). ANSYS/LS-DYNA. In ANSYS/LS-DYNA reference manual, Release 10. 7374 Las Positas Road, Livermore. 21. Long, S. G., & Zhou, Y. C. (2005). Thermal fatigue of particle reinforced metal-matrix composite induced by laser heating and mechanical load. Composites Science and Technology. https://doi.org/10.1016/j.compscitech.2004.12.009 22. Meijer, G., Ellyin, F., & Xia, Z. (2000). Aspects of residual thermal stress/strain in particle reinforced metal matrix composites. Composites Part B-Engineering -COMPOS PART B-ENG, 31, 29–37. https://doi.org/10.1016/S1359-8368(99)00060-8 23. Monaghan, J., & Brazil, D. (1998). Modelling the flow processes of a particle reinforced metal matrix composite during machining. Composites Part A: Applied Science and Manufacturing. https://doi.org/10.1016/s1359-835x(97)00047-x 24. Ozben, T., Kilickap, E., & Çakir, O. (2008). Investigation of mechanical and machinability properties of SiC particle reinforced Al-MMC. Journal of Materials Processing Technology. https://doi.org/10.1016/j.jmatprotec.2007.06.082 25. Pramanik, A., Zhang, L., & Arsecularatne, J. (2007). Micro-Indentation of Metal Matrix Composite - An FEM Investigation. Key Engineering Materials - KEY ENG MAT, 340–341, 563–570.https://doi.org/10.4028/www.scientific.net/KEM.340-341.563 26. Pramanik, A., Zhang, L. C., & Arsecularatne, J. A. (2006). Prediction of cutting forces in machining of metal matrix composites. International Journal of Machine Tools and Manufacture. https://doi.org/10.1016/j.ijmachtools.2005.11.012 27. Rajasekar, S., Pitchai, P. nathan, & Veerapadran, C. (2006). 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