Slot milling of AA7075 reinforced with nano silicon carbide particles – an experimental and finite element approach
Original scientific paper
DOI:
https://doi.org/10.2298/CICEQ240826006CKeywords:
Aluminium nanocomposite, Slot milling, 3D FEM, cutting forces, chip morphologyAbstract
In the current trend, industries prefer to optimise machining processes using finite element-based machining simulation techniques. Aluminium alloy 7075 (AA7075) strengthened with nano Silicon Carbide particles (nSiCp) is utilized by industries as they exhibit good physical and mechanical properties. Slot milling is the essential machining operation to convert the component to the designed shape and size. However, excellent knowledge is required in selecting the appropriate machining parameters such as cutting velocity, feed and cutting tool material to ensure the quality of the components milled. In this research work, slot milling operation is carried out in the sample plates of AA7075 fortified with nSiCp content to 1.5 % of the weight. A 3D Finite Element Model (3D FEM) is developed using ABAQUS software for simulating slot milling operations to understand the influence of machining parameters on cutting forces, chip formation and chip morphology. The cutting force signals predicted by 3D FEM correlates 85 to 90 % with experimental data. The maximum shear stress of 175 MPa and Von Mises stress of 459 MPa were observed at the tool-workpiece interface. This validated 3D FEM facilitate to visualize and investigate the milling process and assists in selecting appropriate machining parameter settings. The effects of cutting velocity and feed on cutting forces, chip characteristics, stress and chip formation are reported.
References
A. Macke, B.F. Schultz, P. Rohatgi, Adv. Mater. Processes 170(3) (2012) 19-23. https://doi.org/10.31399/asm.amp.2012-03.p019.
N. Shetty, S.M. Shahabaz, S.S. Sharma, S. Divakara, Shetty, Compos. Struct. 176 (2017) 790-802. https://doi.org/10.1016/j.compstruct.2017.06.012.
D. Giugliano, N.K. Cho, H. Chen, L. Gentile, Compos. Struct. 218 (2019) 204-216. https://doi.org/10.1016/j.compstruct.2019.03.030.
R. Bach, Aluminium in transport (2020)
Available from: https://www.aluminiumleader.com/application/transport/[accessed 16th August 2024]
Y. Peng, H. Zhao, J. Ye, M. Yuan, L. Tian, Z. Li, Z. Wang, J. Chen, Compos. Struct. 288 (2022) 115425. https://doi.org/10.1016/j.compstruct.2022.115425.
X.D. Nong, Y.L. Jiang, M. Fang, L. Yu, C.Y. Liu, Int. J. Heat Mass Transfer 108 (2017) 1374-1382. https://doi.org/10.1016/j.ijheatmasstransfer.2016.11.108.
K. Palanikumar, N. Muthukrishnan, K.S. Hariprasad, Mach. Sci. Technol. 12(4) (2008) 529-545. https://doi:10.1080/10910340802518850.
K. Giasin, A. Hodzic, V. Phadnis, S. Ayvar- Soberanis, Int. J. Adv. Manuf. Technol. 87(5) (2016) 2041–2061. https://doi:10.1007/s00170-016-8563-y.
M. Aamir, K. Giasin, M. Tolouei-Rad, A. Vafadar, J. Mater. Res. Technol. 9(6) (2020) 12484-12500. https://doi.org/10.1016/j.jmrt.2020.09.003.
M. Bhuvanesh Kumar, R. Parameshwaran, K. Deepandurai, S.M. Senthil, Trans. Indian Inst. Met. (2020). https://doi.org/10.1007/s12666-020-01960-6.
W. Ma, R. Wang, X. Zhou, X. Xie, Proc. Inst. Mech. Eng., Part B 235(1-2) (2021) 265-277. https://doi:10.1177/0954405420932442.
A. Davoudinejad, G. Tosello, P. Parenti, M. Annoni, Micromachines 8(6) 187 (2017). https://doi.org/10.3390/mi8060187.
P. Raghuvaran, M. Suresh, S. Aakash, M. Balaji, K. Dinesh Kumar, S. H. Prasath, IOP Conf. Ser. Mater. Sci. Eng. 995 (2020). https://doi.org/10.1088/1757-899X/995/1/012040
K.H. Cui, C.Z. Ren, G. Chen, Key Eng. Mater. (589–590) (2013) 3-7. https://www.scientific.net/KEM.589-590.3.
U. Usama, A. Hisham, H.A. Mustufa, M.M. Khan, H.A. Kishawy, Adv. Mech. Eng. 13 (2021). https://doi.org/10.1177/16878140211070446.
U. Umer, M.H. Abidi, J.A. Qudeiri, H. Alkhalefah, Mater. Today: Proc. 44 (2021) 764-770. https://doi.org/10.1016/j.matpr.2020.10.679.
L. Zhou, C. Cui, P. Zhang, Int. J. Adv. Manuf. Technol. 91 (2017) 1935–1944. https://doi.org/10.1007/s00170-016-9933-1.
C. Prakash, K.S. Vijay Sekar, J. Balk. Tribol. Assoc. 23(3) (2017) 497-514.
C. Prakash, A. Arockia Selvakumar, J. Prakash, AIP Conf. Proc. 3216(1) (2024) 040002. https://doi.org/10.1063/5.0226489
A.F.V. Pedroso, N.P.V. Sebbe, R.D.F.S.Costa, M.L.S. Barbosa, R.C.M. Sales-Contini, F.J.G. Silva, R.D.S.G. Campilho, A.M.P. de Jesus, An Extended Review. J. Manuf. Mater. Process. 8(1) (2024) 37. https://doi.org/10.3390/jmmp8010037
S. Dodla, K.J Kirpalani Idnani, A. Katyal, Mater. Today: Proc. (2021). https://doi.org/10.1016/j.matpr.2021.01.136.
S. Deshmukh, G. Joshi, A. Ingle, D. Thakur, Mater. Today: Proc. 46 (2021) 8410-8416. https://doi:10.1016/j.matpr.2021.03.450.
Z. Liangchi, Wu. Zhonghuai, Wu. Chuhan, Wu. Qi, Compos. B Eng. 241, (2022) 110023, https://doi.org/10.1016/j.compositesb.2022.110023.
C. Prakash, K.S. Vijay Sekar, Adv. Sci., Eng. Med. 10(3) (2018) 308-312. https://doi.org/10.1166/asem.2018.2125.
C. Prakash, K.S. Vijay Sekar, J. Braz. Soc. Mech. Sci. Eng. 40(6) (2018) 279. https://doi.org/10.1007/s40430-018-1195-4.
C. Prakash, K.S. Vijay Sekar, IOSR J. Eng. (2018) 22-28. https://iosrjen.org/Papers/ICPRASET%202K18/surya/Volume%201/auto/5.%2022-28.pdf
C. Prakash, K.S. Vijay Sekar, Lect. Notes Mech. Eng. (2019) 81-89. https://doi.org/10.1007/978-981-13-1724-8_8.
C. Prakash, K.S. Vijay Sekar, IOP Conf. Ser. Mater. Sci. Eng. (2021). https://doi.org/10.1088/1757-899X/1128/1/012050.
C. Prakash, A. Arockia Selvakumar, K.S. Vijay Sekar, Mater. Today: Proc. (2023). https://doi.org/10.1016/j.matpr.2023.08.234.
C. Prakash, Int. J. Interact. Des. Manuf. (2024). https://doi.org/10.1007/s12008-024-02089-2
J. Prakash, S. Gopalakannan, Silicon 13 (2021) 409-432. https://doi.org/10.1007/s12633-020-00434-0.
J. Prakash, S. Gopalakannan, V.K. Chakravarthy, Silicon 14(4) (2022) 1683-1694. https://doi.org/10.1007/s12633-021-00979-8.
H. Liu, W. Zhu, H. Dong, Ke. Yinglin, Mechatronics 46 (2017) 101–114. https://doi:10.1016/j.mechatronics.2017.07.004.
R.K. Bhushan, Adv. Compos. Hybrid Mater. 4(1) (2021) 74-85. https://doi.org/10.1007/s42114-020-00175-z.
I. Boughdiri, T. Mabrouki, R. Zitoune, K. Giasin, M.F. Ameur, Compos. Struct. 304 (2023) 116458. https://doi.org/10.1016/j.compstruct.2022.116458.
T.Ozben, E. Kilickap, O.Çakır, J. Mater. Process. Technol. 198(1–3) (2008) 220-225. https://doi.org/10.1016/j.jmatprotec.2007.06.082.
S.Deshmukh, G. Joshi, A. Ingle, D.S. Thakur, Mater. Today: Proc. 46(17) (2021) 8410-8416. https://doi.org/10.1016/j.matpr.2021.03.450.
S.S. Babu, C. Dhanasekaran, G. Anbuchezhiyan, K. Palani, Eng. Res. Express. 4 (2022) 025036. https://doi.org/10.1088/2631-8695/ac7038.
D. Simulia, Abaqus 6.14 User’s manual (2014) Dassault systems. http://50.16.225.63/v6.14/
CATIA V5R14, User Manual (2014) Dassault systems. https://www.maruf.ca/files/catiahelp/CATIA_P3_default.htm
T. Mabrouki, F. Girardin, M. Asad, J.F. Rigal, Int. J. Mach. Tools Manuf. 48 (2008) 1187–97. https://doi.org/10.1016/j.ijmachtools.2008.03.013.
C. Prakash, J. Prakash, Proc. Inst. Mech. Eng., Part D (2024). https://doi.org/10.1177/09544070241254148.
G. Johnson, W. Cook, Eng. Fract. Mech. 21(1) (1985) 31–48. https://doi.org/10.1016/00137944(85)90052-9.
S. Rasaee, A.H. Mirzaei, D. Almasi, Bull. Mater. Sci. 43(1) (2020) 1-8. https://doi.org/10.1007/s12034-019-1987-x.
J.Y. Sheikh-Ahmad, Textbook of Machining of Polymer Composites, Springer New York, NY (2009). https://doi.org/10.1007/978-0-387-68619-6.
H. Yu, Z. He, J. Li, Int. J. Adv. Manuf. Technol. 124 (2023) 97–110. https://doi.org/10.1007/s00170-022-10476-w.
G. Li, M. Liu, S. Zhao, Mach. Sci. Technol. 25(4) (2021) 558–584 https://doi.org/10.1080/10910344.2020.1855651.
C. Prakash, J. Prakash, Arch. Metall. Mater. 70(2) (2025) [Accepted article].
Downloads
Published
Issue
Section
License
Copyright (c) 2023 Prakash Chakrapani, Prakash Jayaraman

This work is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.
Authors who publish with this journal agree to the following terms:
Authors retain copyright and grant the journal right of first publication with the work simultaneously licensed under a Creative Commons Attribution License that allows others to share the work with an acknowledgement of the work's authorship and initial publication in this journal.
Authors grant to the Publisher the following rights to the manuscript, including any supplemental material, and any parts, extracts or elements thereof:
- the right to reproduce and distribute the Manuscript in printed form, including print-on-demand;
- the right to produce prepublications, reprints, and special editions of the Manuscript;
- the right to translate the Manuscript into other languages;
- the right to reproduce the Manuscript using photomechanical or similar means including, but not limited to photocopy, and the right to distribute these reproductions;
- the right to reproduce and distribute the Manuscript electronically or optically on any and all data carriers or storage media – especially in machine readable/digitalized form on data carriers such as hard drive, CD-Rom, DVD, Blu-ray Disc (BD), Mini-Disk, data tape – and the right to reproduce and distribute the Article via these data carriers;
- the right to store the Manuscript in databases, including online databases, and the right of transmission of the Manuscript in all technical systems and modes;
- the right to make the Manuscript available to the public or to closed user groups on individual demand, for use on monitors or other readers (including e-books), and in printable form for the user, either via the internet, other online services, or via internal or external networks.