Vol.:(0123456789) 1 3 Journal of the Brazilian Society of Mechanical Sciences and Engineering (2019) 41:146 https://doi.org/10.1007/s40430-019-1649-3 TECHNICAL PAPER Evaluation of tool wear in high‑speed face milling of Al/SiC metal matrix composites Reza Ghoreishi 1  · Amir H. Roohi 2  · Amir Dehghan Ghadikolaei 3 Received: 26 December 2018 / Accepted: 18 February 2019 / Published online: 26 February 2019 © The Brazilian Society of Mechanical Sciences and Engineering 2019 Abstract In recent years, a new generation of composite materials has been introduced as metal matrix composites (MMCs) in order to simultaneously provide higher strength and stifness. Industrial interests resulted in deep investigations and researches on machinability of MMCs and especially in the feld of high-speed machining. High-speed machining processes ofer a higher machining efciency and reduced cost of the process, which made them the process of interest in many manufacturing industries. However, matrix reinforcement by addition of hard particle phases to the MMCs signifcantly increases machining difculty, tool wear, surface quality deterioration and overall fabrication costs. In the current research, the cutting speed, feed rate, depth of cut, presence of cryogenic coolant and their efect on the tool wear of high-speed machining of Al/SiC MMC reinforced with 15 wt% SiC particles have been investigated. The results have shown that silicon carbide particles in the aluminum matrix cause a severe tool wear. However, the severity of tool wear has decreased by applying a cryogenic cooling. Keywords Metal matrix composites (MMCs) · High-speed machining · Cryogenic cooling · Aluminum/silicon carbide (Al/ SiC) · Tool wear 1 Introduction High-speed machining is an interesting process due to its high material removal rate (MMR), low cutting forces, high surface quality and lower processing time, while it increases the manufacturing efciency [1]. In addition, high wear resistance, thermal stability, strength/weight ratio and cor- rosion resistance of MMCs compared to the original matrix materials increased their applications in various industries [2]. Rawl et al. [3] have introduced huge benefts of MMCs in automotive and aerospace applications thanks to their lightweight and reliable mechanical properties. Many met- als can be used as matrix and reinforcement particles that increase fexibility in designing an application of MMC with the desired properties. These materials include copper, tung- sten, magnesium, titanium, nickel, iron, etc. [4]. Numerous studies have investigated the properties of MMCs in depth. Gireesh et al. [5] have investigated the mechanical properties of reinforced Al MMC. They have reported enhanced mechanical properties such as hardness, tensile and impact strength. Voyiadjis et al. [6] have stud- ied inelasticity and micromechanics of MMCs. However, aluminum-based MMCs with SiC and alumina (Al 2 O 3 ) reinforcement particles are gaining more attention due to availability and superior mechanical properties. In addi- tion, Al/SiC MMCs demonstrate good thermal stability in heat transfer applications [7, 8]. Similar to many difcult- to-cut alloys and materials (i.e., nickel-based superalloys, NiTi alloys, tungsten, etc.), MMCs are challenging materials when it comes to machining [9]. Machining of MMCs is investigated in depth by many researchers as it is one of the most crucial steps of fabricating these parts. Pramanik et al. [10] have studied cutting force prediction in the machin- ing of Al-based MMC with SiC and alumina reinforcement particles. They have calculated the chip formation force Technical Editor: Lincoln Cardoso Brandão. * Amir H. Roohi Amir.roohi@qiau.ac.ir 1 Department of Mechanical Engineering, Semnan University, Semnan, Iran 2 Department of Mechanical Engineering, Faculty of Industrial and Mechanical Engineering, Qazvin Branch, Islamic Azad University, Qazvin, Iran 3 School of Mechanical, Manufacturing and Industrial Engineering, Oregon State University, Corvallis, OR 97331, USA