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<p>The applications of nanocomposites in aerospace, automotive and biomedical sectors are rapidly expanding, but challenges in understanding their deformation behavior persist, necessitating further study as current research remains in a nascent stage. This work examines the machinability of Mg-Al<sub>2</sub>O<sub>3</sub> nanocomposites, driven by their high strength-to-weight ratio and cost-effectiveness. Despite the increasing interest in nanocomposites, very few studies have examined the machinability of Mg-Al<sub>2</sub>O<sub>3</sub> with varying reinforcement levels. Moreover, the combined influence of machining parameters, cutting inserts and reinforcement volume remains underexplored, representing a significant gap in literature. Turning experiments were performed using varying nano-Al<sub>2</sub>O<sub>3</sub> reinforcements (2.5, 5%), cutting tool inserts (WC, PCD), speeds (71, 133 and 173&#xa0;m/min) and feeds (0.12, 0.14 and 0.16&#xa0;mm/rev) under dry conditions. Results showed that increasing cutting speed reduced the cutting force by 52.3% for WC and 28.4% for PCD inserts, primarily due to thermal softening. PCD tools lowered cutting force by 23.6% compared to WC, indicating superior tooling and wear resistance. Higher reinforcement (5% Al<sub>2</sub>O<sub>3</sub>) increased the cutting force by 22% at low speeds but improved the surface roughness by 35% at high speeds. PCD inserts achieved a 69.9% Ra reduction at 5% reinforcement, while WC showed a 58.9% improvement. PCD tools achieved optimal results with continuous chip formation at high speeds, while WC tools performed better with lower reinforcement and speed. Reinforcement levels and cutting speeds critically influenced chip morphology and the material removal mode (brittle versus ductile). Overall, better machining performance was achieved using PCD inserts at a cutting speed of 173&#xa0;m/min and feed of 0.12&#xa0;mm/rev, where cutting force was minimized, and surface roughness improved by nearly 70%. WC inserts were most effective at moderate speeds (133&#xa0;m/min) and lower reinforcement levels (2.5% Al<sub>2</sub>O<sub>3</sub>), with stable forces and acceptable surface finish.</p>

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Machinability of Mg-Al2O3 Nanocomposites: Effects of Volume Percentage and Cutting Inserts

  • 期刊论文

  • 发表日期：

    2025年6月4日

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  • K. S. Vijay Sekar,
  • K. Gobivel,
  • J. Shrinath,
  • S. Rohit Kumar,
  • P. Shreenivasan

摘要

The applications of nanocomposites in aerospace, automotive and biomedical sectors are rapidly expanding, but challenges in understanding their deformation behavior persist, necessitating further study as current research remains in a nascent stage. This work examines the machinability of Mg-Al2O3 nanocomposites, driven by their high strength-to-weight ratio and cost-effectiveness. Despite the increasing interest in nanocomposites, very few studies have examined the machinability of Mg-Al2O3 with varying reinforcement levels. Moreover, the combined influence of machining parameters, cutting inserts and reinforcement volume remains underexplored, representing a significant gap in literature. Turning experiments were performed using varying nano-Al2O3 reinforcements (2.5, 5%), cutting tool inserts (WC, PCD), speeds (71, 133 and 173 m/min) and feeds (0.12, 0.14 and 0.16 mm/rev) under dry conditions. Results showed that increasing cutting speed reduced the cutting force by 52.3% for WC and 28.4% for PCD inserts, primarily due to thermal softening. PCD tools lowered cutting force by 23.6% compared to WC, indicating superior tooling and wear resistance. Higher reinforcement (5% Al2O3) increased the cutting force by 22% at low speeds but improved the surface roughness by 35% at high speeds. PCD inserts achieved a 69.9% Ra reduction at 5% reinforcement, while WC showed a 58.9% improvement. PCD tools achieved optimal results with continuous chip formation at high speeds, while WC tools performed better with lower reinforcement and speed. Reinforcement levels and cutting speeds critically influenced chip morphology and the material removal mode (brittle versus ductile). Overall, better machining performance was achieved using PCD inserts at a cutting speed of 173 m/min and feed of 0.12 mm/rev, where cutting force was minimized, and surface roughness improved by nearly 70%. WC inserts were most effective at moderate speeds (133 m/min) and lower reinforcement levels (2.5% Al2O3), with stable forces and acceptable surface finish.