Fabrication and machining of aluminum-reinforced graphite metal matrix composites

Abstract

Shaping of aluminum alloys by chip removal has increased significantly in the industry. Accordingly, issues aiming to reduce friction between the tool and the workpiece and to increase tool life have gained importance. As a result, despite the common use of coolant, minimal lubrication, and cryogenic cooling, it is expected that studies for dry processing will increase day by day due to environmental damage and high costs of the coolant. In this study, the effects of reinforcing solid lubricants in aluminum alloys onto the tool wear and surface integrity during the cylindrical turning of composites were investigated. As a result of the study, it was measured that the reinforcement material graphite reduces the temperatures occurring in the cutting zone in the turning process by an average of 22.5%. Accordingly, improvements in surface roughness values were achieved, cutting tool wear was reduced and tool life was increased by approximately 27%. Within the scope of this study, it can be stated that sustainable production is achieved without using cutting fluids that are costly, harmful to the environment and human health.