Effect of Intermetallics and Drill Materials on the Machinability of Al-Si Cast Alloys
The present study was conducted on the machinability of 396 alloy (containing approximately 11% Si) and B319.2 alloy mainly to emphasize the effects of Fe-intermetallics, i.e., <i>α</i>-Fe, <i>β</i>-Fe, and sludge. The results demonstrate that the presence of <i>sludge&...
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MDPI AG
2022-01-01
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| Online Access: | https://www.mdpi.com/1996-1944/15/3/916 |
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| author | Yasser Zedan Guillermo H. Garza-Elizondo Mahmoud Tash Agnes M. Samuel Herbert W. Doty Victor Songmene Fawzy Hosny Samuel |
| author_facet | Yasser Zedan Guillermo H. Garza-Elizondo Mahmoud Tash Agnes M. Samuel Herbert W. Doty Victor Songmene Fawzy Hosny Samuel |
| author_sort | Yasser Zedan |
| collection | DOAJ |
| description | The present study was conducted on the machinability of 396 alloy (containing approximately 11% Si) and B319.2 alloy mainly to emphasize the effects of Fe-intermetallics, i.e., <i>α</i>-Fe, <i>β</i>-Fe, and sludge. The results demonstrate that the presence of <i>sludge</i> in the form of hard spots has a significant effect on cutting forces and tool life, in that it decreases drill life by 50% compared to the base alloy. The formation of the <i>α</i>-Fe phase in the M1 base alloy has a beneficial effect on tool life in that this alloy produces the highest number of holes drilled compared to alloys containing <i>sludge</i> or <i>β</i>-Fe; this result may be explained by the fact that the formation of the <i>α</i>-Fe intermetallic, with its rounded Chinese script morphology and its presence within <i>α</i>-Al dendrites, is expected to improve matrix homogeneity via hardening of the soft <i>α</i>-Al dendrites. Increasing the Fe-content from 0.5% to 1% in the 396-T6 alloy containing 0.5% Mn produces a distinct improvement in alloy machinability in terms of cutting force and tool life. The addition of Fe and/or Mn appears to have no discernible effect on the build-up edge area (BUE) and chip shape. |
| first_indexed | 2024-03-09T23:37:09Z |
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| id | doaj.art-921c446959d148c0b9d2e8709a9083cc |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-09T23:37:09Z |
| publishDate | 2022-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-921c446959d148c0b9d2e8709a9083cc2023-11-23T16:59:14ZengMDPI AGMaterials1996-19442022-01-0115391610.3390/ma15030916Effect of Intermetallics and Drill Materials on the Machinability of Al-Si Cast AlloysYasser Zedan0Guillermo H. Garza-Elizondo1Mahmoud Tash2Agnes M. Samuel3Herbert W. Doty4Victor Songmene5Fawzy Hosny Samuel6École de Technologie Supérieure, Département de Génie Mécanique, Montréal, QC H3C 1K3, CanadaDépartement des Sciences Appliquées, Université du Québec à Chicoutimi, Chicoutimi, QC G7H 2B1, CanadaDepartment of Metallurgical Engineering Program, Cairo University, Cairo 12613, EgyptÉcole de Technologie Supérieure, Département de Génie Mécanique, Montréal, QC H3C 1K3, CanadaGeneral Motors Global Technology Center, Warren, MI 48093-2350, USAÉcole de Technologie Supérieure, Département de Génie Mécanique, Montréal, QC H3C 1K3, CanadaDépartement des Sciences Appliquées, Université du Québec à Chicoutimi, Chicoutimi, QC G7H 2B1, CanadaThe present study was conducted on the machinability of 396 alloy (containing approximately 11% Si) and B319.2 alloy mainly to emphasize the effects of Fe-intermetallics, i.e., <i>α</i>-Fe, <i>β</i>-Fe, and sludge. The results demonstrate that the presence of <i>sludge</i> in the form of hard spots has a significant effect on cutting forces and tool life, in that it decreases drill life by 50% compared to the base alloy. The formation of the <i>α</i>-Fe phase in the M1 base alloy has a beneficial effect on tool life in that this alloy produces the highest number of holes drilled compared to alloys containing <i>sludge</i> or <i>β</i>-Fe; this result may be explained by the fact that the formation of the <i>α</i>-Fe intermetallic, with its rounded Chinese script morphology and its presence within <i>α</i>-Al dendrites, is expected to improve matrix homogeneity via hardening of the soft <i>α</i>-Al dendrites. Increasing the Fe-content from 0.5% to 1% in the 396-T6 alloy containing 0.5% Mn produces a distinct improvement in alloy machinability in terms of cutting force and tool life. The addition of Fe and/or Mn appears to have no discernible effect on the build-up edge area (BUE) and chip shape.https://www.mdpi.com/1996-1944/15/3/916drillingcutting forcescutting momentsintermetallicsfree cutting elementstool life |
| spellingShingle | Yasser Zedan Guillermo H. Garza-Elizondo Mahmoud Tash Agnes M. Samuel Herbert W. Doty Victor Songmene Fawzy Hosny Samuel Effect of Intermetallics and Drill Materials on the Machinability of Al-Si Cast Alloys Materials drilling cutting forces cutting moments intermetallics free cutting elements tool life |
| title | Effect of Intermetallics and Drill Materials on the Machinability of Al-Si Cast Alloys |
| title_full | Effect of Intermetallics and Drill Materials on the Machinability of Al-Si Cast Alloys |
| title_fullStr | Effect of Intermetallics and Drill Materials on the Machinability of Al-Si Cast Alloys |
| title_full_unstemmed | Effect of Intermetallics and Drill Materials on the Machinability of Al-Si Cast Alloys |
| title_short | Effect of Intermetallics and Drill Materials on the Machinability of Al-Si Cast Alloys |
| title_sort | effect of intermetallics and drill materials on the machinability of al si cast alloys |
| topic | drilling cutting forces cutting moments intermetallics free cutting elements tool life |
| url | https://www.mdpi.com/1996-1944/15/3/916 |
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