Micro-Structural Analysis of Chip Formation During Orthogonal Machining of Al/SiCp Composites

[+] Author and Article Information
S. S. Joshi, N. Ramakrishnan

Department of Mechanical Engineering, Indian Institute of Technology, Bombay, Powai, Mumbai, 400 076 India

P. Ramakrishnan

Department of Metallurgical Engineering, Indian Institute of Technology, Bombay, Powai, Mumbai, 400 076 India

J. Eng. Mater. Technol 123(3), 315-321 (Nov 17, 2000) (7 pages) doi:10.1115/1.1356026 History: Received April 23, 1999; Revised November 17, 2000
Copyright © 2001 by ASME
Your Session has timed out. Please sign back in to continue.


Maruyama, B., and Hunt, Jr., W. H., 1999, “Discontinuously Reinforced Aluminum: Current status and future directions,” JOM, Nov., pp. 59–61.
Kevorkijan, V. M., 1999, “Aluminum composites for automotive applications: A global perspective,” JOM, Nov., pp. 54–58.
Hunt, Jr., W. H., and Maruyama, B., 1999, “The world still won’t beat a path to your door: Transitioning DRA to the marketplace,” JOM, Nov. pp. 62–64.
Lloyd,  D. J., 1994, “Particulate reinforced aluminum and magnesium matrix composites,” Int. Mater. Rev., 39, No. 1, pp. 1–23.
McKimpson, M. G., Pohlenz, E. L., and Thompson, S. R., 1993, “Evaluating the mechanical properties of commercial DRA,” JOM, Jan, pp. 26–29.
Joshi,  S. S., Ramakrishnan,  N., Sarathy,  D., and Ramakrishnan,  P., 1998, “Study of cutting forces while turning Al/SiCp composites using rotary carbide tools,” Mater. Manuf. Processes, 13, No. 1, pp. 65–84.
Joshi,  S. S., Ramakrishnan,  N., Nagarwalla,  H. E., and Ramakrishnan,  P., 1999, “Wear of rotary carbide tools in machining of Al/SiCp composites,” Wear, 230, pp. 124–132.
Brun,  M. K., and Lee,  M., 1985, “Wear characteristics of various hard materials for machining of SiC-reinforced aluminum alloy,” Wear, 104, pp. 21–29.
Cronjager,  L., and Melster,  D., 1992, “Machining of fibre- and particulate reinforced aluminum,” Ann. CIRP, 41, No. 1, pp. 63–66.
Tomac,  N., and Tonnessen,  K., 1992, “Machinability of particulate aluminum matrix composites,” Ann. CIRP, 41, No. 1, pp. 55–58.
Weinert,  K., and Konig,  W., 1993, “A Consideration of tool wear mechanisms when machining metal matrix composites,” Ann. CIRP, 42, No. 1, pp. 95–98.
Monaghan, J., 1994, “The use of quick-stop test to study the chip formation of a SiC/Al composite,” Proc Adv Mater, Vol. 9, pp. 170–179.
El-Gallab,  M., and Sklad,  M., 1998, “Machining of Al/SiC particulate metal-matrix composites part-I: Tool Performance,” J. Mater. Process. Technol., 83, pp. 151–158.
Iwata,  K., and Ueda,  K., 1976, “The significance of dynamic crack behavior in chip formation,” Ann. CIRP, 25, No. 1, pp. 65–70.
Joshi,  S. S., Ramakrishnan,  N., and Ramakrishnan,  P., 1999, “Analysis of chip breaking during orthogonal machining of Al/SiCp composites,” J. Mater. Process. Technol., 88, pp. 90–96.
Joshi, S. S., 1997, “Some studies on machining of squeeze cast and extruded Al/SiCp composites,” Ph.D. thesis, Indian Institute of Technology, Bombay, 400 076 India.
Ponkshe,  G. R., 1967, “A new explanation of the phenomenon of chip curling during machining,” ASME J. Eng. Ind., 89, May, pp. 376–379.
Nakayama,  K., Arai,  M., and Kanda,  T., 1998, “Machining characteristics of hard materials,” Ann. CIRP, 37, No. 1, pp. 89–92.
Shaw,  M. C., and Vyas,  A., 1993, “Chip formation in machining of hardened steel,” Ann. CIRP, 42, No. 1, pp. 29–33.
Joshi, S. S., Ramakrishnan, N., Chaturvedi, R. C., and Ramakrishnan, P., 1996, “Study of flow stress for Al/SiCp composites at elevated temperatures,” Processing, Properties and Applications of Cast Metal Matrix Composites, P. K. Rohatgi, ed., Proc. of the TMS Annual Meeting, Cincinnati, Ohio, Oct, pp. 119–126.
Ueda,  N., Matsuo,  T., and Uhera,  K., 1982, “An analysis of saw-toothed chip formation,” Ann. CIRP, 31, No. 1, pp. 81–84.
Zener, C., 1948, “The micro-mechanism of fracture,” Fracturing of Metals, ASM, pp. 3–31.
Recht,  R. F., 1964, “Catastrophic thermoplastic shear,” ASME J. Appl. Mech., 31, June, pp. 89–193.
Kudo,  H., and Tsubouchi,  M., 1971, “Strain concentration due to heat generation in fast plastic deformation,” Ann. CIRP, XVIV, pp. 225–230.
Spanns,  C., 1972, “A Treatise on the streamlines and the stress, strain and strain rate distributions, and on the stability in the primary shear zone in metal cutting,” ASME J. Eng. Ind., 94, May, pp. 688–696.
Enaharo,  H. E., and Oxley,  P. L. B., 1961, “An investigation of transition from a continuous to a discontinuous chip in orthogonal cutting,” Int. J. Mech. Sci., 3, pp. 145–156.
Shaw,  M. C., 1980, “A new mechanism of plastic flow,” Int. J. Mech. Sci., 22, pp. 673–686.
De Chiffre,  L., and Wanheim,  T., 1985, “What can we do about chip formation mechanics?” Ann. CIRP, 34, No. 1, pp. 129–132.
Dieter, G. E., 1988, Mechanical Metallurgy, McGraw-Hill, N.Y.


Grahic Jump Location
Reinforcement distribution in Al/SiC/20p composites
Grahic Jump Location
(a–d) Longitudinal c/s of chip showing STP (on shaper, speed: 16.5 m/min, depth of cut: 0.12 mm)
Grahic Jump Location
Enlarged longitudinal c/s of Al/SiC/30p (on shaper, speed: 16.5 m/min; depth of cut: 0.12 mm)
Grahic Jump Location
Longitudinal c/s of chip (Al/SiC/20p) (on lathe, speed: 68 m/min; depth of cut: 0.12 mm)
Grahic Jump Location
(a–b) SEM micrographs of chip roots (a) Chip root, (b) gross fracture (on lathe: speed: 22 m/min; depth of cut: 0.12 mm)
Grahic Jump Location
Model of deformation on shear plane
Grahic Jump Location
(a–b) Distribution of stresses on (a) tool face (b) shear plane 27
Grahic Jump Location
Model of distribution of stresses on the shear plane
Grahic Jump Location
State of stress on the shear plane




Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In