A Numerical Simulation of Machining 6061 Syntactic Foams Reinforced with Hollow Al<sub>2</sub>O<sub>3</sub> Shells
Aluminum closed cell syntactic foams possess reduced density, higher peak compression strength, and lower coefficient of thermal expansion and thermal conductivity compared to metal alloys. However, the industrial mass production of these complex material systems presents a significant problem in th...
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| Format: | Article |
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MDPI AG
2022-03-01
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| Series: | Metals |
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| Online Access: | https://www.mdpi.com/2075-4701/12/4/596 |
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| author | Kevin Thomas Sathish Kannan Mohammad Nazzal Salman Pervaiz Ramanujam Karthikeyan |
| author_facet | Kevin Thomas Sathish Kannan Mohammad Nazzal Salman Pervaiz Ramanujam Karthikeyan |
| author_sort | Kevin Thomas |
| collection | DOAJ |
| description | Aluminum closed cell syntactic foams possess reduced density, higher peak compression strength, and lower coefficient of thermal expansion and thermal conductivity compared to metal alloys. However, the industrial mass production of these complex material systems presents a significant problem in the form of poor machinability. In order to address this concern and to increase the use of this potential cost- and energy-saving system, a two-dimensional numerical model using the AdvantEdge<sup>TM</sup> machining software was developed. For the verification of the numerical model, machining trials in dry conditions were conducted on different samples using a Sandvik<sup>TM</sup> carbide-coated insert having a 6° rake angle and a 7° clearance angle. The hollow alumina shell diameter and volume fraction were found to profoundly affect the magnitude of the generated machining forces. This study showed an increase in machining force by almost 25% for syntactic foams reinforced with hollow alumina shells of higher volume fraction and coarser diameters. The cutting conditions to obtain a favorable stress diastribution in the syntactic foam’s machined sub-surface were identified. |
| first_indexed | 2024-03-09T13:18:41Z |
| format | Article |
| id | doaj.art-a595f967f2cb4783ad958a07b3da6bb5 |
| institution | Directory Open Access Journal |
| issn | 2075-4701 |
| language | English |
| last_indexed | 2024-03-09T13:18:41Z |
| publishDate | 2022-03-01 |
| publisher | MDPI AG |
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| series | Metals |
| spelling | doaj.art-a595f967f2cb4783ad958a07b3da6bb52023-11-30T21:32:48ZengMDPI AGMetals2075-47012022-03-0112459610.3390/met12040596A Numerical Simulation of Machining 6061 Syntactic Foams Reinforced with Hollow Al<sub>2</sub>O<sub>3</sub> ShellsKevin Thomas0Sathish Kannan1Mohammad Nazzal2Salman Pervaiz3Ramanujam Karthikeyan4Department of Mechanical Engineering, American University of Sharjah, Sharjah P.O. Box 26666, United Arab EmiratesDepartment of Mechanical Engineering, American University of Sharjah, Sharjah P.O. Box 26666, United Arab EmiratesDepartment of Mechanical Engineering, American University of Sharjah, Sharjah P.O. Box 26666, United Arab EmiratesDepartment of Mechanical Engineering, Rochester Institute of Technology, Dubai P.O. Box 341055, United Arab EmiratesDepartment of Mechanical Engineering, BITS Pilani, Dubai P.O. Box 345055, United Arab EmiratesAluminum closed cell syntactic foams possess reduced density, higher peak compression strength, and lower coefficient of thermal expansion and thermal conductivity compared to metal alloys. However, the industrial mass production of these complex material systems presents a significant problem in the form of poor machinability. In order to address this concern and to increase the use of this potential cost- and energy-saving system, a two-dimensional numerical model using the AdvantEdge<sup>TM</sup> machining software was developed. For the verification of the numerical model, machining trials in dry conditions were conducted on different samples using a Sandvik<sup>TM</sup> carbide-coated insert having a 6° rake angle and a 7° clearance angle. The hollow alumina shell diameter and volume fraction were found to profoundly affect the magnitude of the generated machining forces. This study showed an increase in machining force by almost 25% for syntactic foams reinforced with hollow alumina shells of higher volume fraction and coarser diameters. The cutting conditions to obtain a favorable stress diastribution in the syntactic foam’s machined sub-surface were identified.https://www.mdpi.com/2075-4701/12/4/596machiningaluminumsyntactic foamnumerical modelFE simulation |
| spellingShingle | Kevin Thomas Sathish Kannan Mohammad Nazzal Salman Pervaiz Ramanujam Karthikeyan A Numerical Simulation of Machining 6061 Syntactic Foams Reinforced with Hollow Al<sub>2</sub>O<sub>3</sub> Shells Metals machining aluminum syntactic foam numerical model FE simulation |
| title | A Numerical Simulation of Machining 6061 Syntactic Foams Reinforced with Hollow Al<sub>2</sub>O<sub>3</sub> Shells |
| title_full | A Numerical Simulation of Machining 6061 Syntactic Foams Reinforced with Hollow Al<sub>2</sub>O<sub>3</sub> Shells |
| title_fullStr | A Numerical Simulation of Machining 6061 Syntactic Foams Reinforced with Hollow Al<sub>2</sub>O<sub>3</sub> Shells |
| title_full_unstemmed | A Numerical Simulation of Machining 6061 Syntactic Foams Reinforced with Hollow Al<sub>2</sub>O<sub>3</sub> Shells |
| title_short | A Numerical Simulation of Machining 6061 Syntactic Foams Reinforced with Hollow Al<sub>2</sub>O<sub>3</sub> Shells |
| title_sort | numerical simulation of machining 6061 syntactic foams reinforced with hollow al sub 2 sub o sub 3 sub shells |
| topic | machining aluminum syntactic foam numerical model FE simulation |
| url | https://www.mdpi.com/2075-4701/12/4/596 |
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