Graphite/Al2O3 reinforced aluminum for milling of metal matrix composites inspection of tool wear

Aluminum metal matrix composites (AMMC) are widely used in industry due to their resistance to corrosion and abrasion, specific gravity, ability to work at high temperatures, supply and production facilities. During the processing of composites, undesirable high temperatures occur due to the wear between the tool and the part. In order to eliminate this temperature, although traditional cutting fluids meet the need, they affect human health with the damage they cause to the environment. In order to eliminate this factor, solid lubricant materials have started to gain a place in the industry and become the subject of researchers. Solid lubricants play a role in reducing wear and friction in the areas where they are added. It is actively used in the industry for forming parts resistant to corrosion and wear in bearings subjected to movements. Considering the usage patterns, its use as an additional material to the Minimum Quantity Lubrication (MQL) systems, adding it to the cutting area in pure form and coating the cutting tools has been included in the research topics. The aim of this study is to produce AMMCs with self-lubricating properties and examine their processability in dry environment. Mix casting method was used in the production of AMMCs. Al7075 alloy was chosen as the matrix material, and solid lubricant graphite (5-10-15%) and Al2O3 ceramic (5%) materials were selected as reinforcement materials. XRD, SEM, EDX, DTA / TGA and DSC analyzes were performed for the characterization of AMMCs. In addition, tensile and micro hardness tests were carried out to determine the effect of reinforcement materials on mechanical properties. In order to examine the machinability of AMMCs, milling operations were performed at three different speed and feed parameters in dry environment. After the milling process, it was determined that the temperatures in the cutting zone decreased, tool wear decreased and surface roughness values improved with the increasing weight of graphite reinforcement.