199 Journal of Engineering, Mechanics and Architecture www. grnjournal.us AMERICAN Journal of Engineering, Mechanics and Architecture Volume 02, Issue 6, 2024 ISSN (E): 2993-2637 Characterizing AA6351/Tib2 Composite Drilling on Abrasive Water Jet Machining Manikandan S Department of Mechanical Engineering, Dhaanish Ahmed College of Engineering, Chennai, Tamil Nadu, India. manikandan@dhaanishcollege.in Gandhi M Department of Mechanical Engineering, Dhaanish Ahmed College of Engineering, Chennai, Tamil Nadu, India. gandhi@dhaanishcollege.in B. Vaidianathan Department of Electronics & Communication Engineering Dhaanish Ahmed College of Engineering, Chennai, Tamil Nadu, India. vaidianathan@dhaanishcollege.in Abstract: Aluminum is a material that is malleable, soft, and resistant to corrosion. Additionally, it has a high electrical conductivity. It finds widespread application in the production of conductor cables and foil, but it must be alloyed with other elements in order to achieve the greater strengths required for usage in other applications. Aluminum, which has a strength-to-weight ratio that is superior to that of steel, is one of the lightest engineering metals you can find. The purpose of this work is to investigate the microstructural and drilling characterisation of AA6351/TiB2 composites that were produced using the stir casting method. In order to determine the process parameters, the weight percentage of TiB2 was varied between 5 and 10. In order to determine the hardness and optical microstructure of the composites that were fabricated, as well as the effects of machining parameters such as surface roughness and circularity of the composites, the experiments were carried out by using Al-6351 as the workpiece. The drilling process was carried out by an abrasive water jet machine. The value of the result demonstrates that the hardness value has been steadily increasing. Keywords: AA6351, Tib2, stir casting, optical microscope, Vickers hardness test, surface roughness. Introduction When at least two materials, such as metal and a matrix composite, are combined, the result is an improved set of characteristics compared to the parts used alone. Composites' efficiency and adaptability stem from the wide variety of techniques and materials that can go into their mailto:vaidianathan@dhaanishcollege.in 200 Journal of Engineering, Mechanics and Architecture www. grnjournal.us construction [6-11]. As a rule, their solutions outperform conventional materials in terms of weight, strength, and longevity. Composites made of metal and strong ceramic reinforcements are called metal matrix composites, or MMCs. Their excellent corrosion resistance, high modulus, and wear resistance are just a few of their exceptional features. Composites like these can have reinforcements in the form of whiskers, short or continuous fibres, or even particles. One of the most common types of composites is particle-reinforced aluminium alloy composites [12-19]. A few examples of their many engineering uses include cylinder block liners, drive shafts, pistons, bicycle frames, and automobiles. When it comes to applications that demand long-term resilience to harsh environments, including high temperatures, metal matrices are better than polymeric ones. Applications necessitating strong transverse strength and modulus in addition to compressive strength for the composite should take this into account, since metals often have greater yield strengths and moduli than polymers [20-26]. When specifying, keep in mind that composites, like all engineering materials, have their own set of advantages and disadvantages. To be clear, composites aren't always the best choice. One of the main reasons composites have been developed is that their final qualities may be tailored by adjusting the combination of reinforcement and matrix. This article uses the sat casting method to produce a new composite material from AA6351 base material reinforced with TiB2 [27-35]. If the final component needs to be fire-resistant, for example, a fire-retardant matrix can be utilised during development to ensure this feature and others are included. After that, the composite material's mechanical qualities, such as its hardness and surface roughness, are determined by a battery of tests. A profilometer was used to ascertain the surface roughness value, while the Vickers hardness test was used to ascertain the hardness value. To find out how round and circular the drilled hole was, the composite material was then machined using an abrasive water jet machine. By adjusting the weight percentage of TiB2, V. Mohanavel determined the hardness, compression, and tensile strength values for AA6351/TiB2 [36-42]. Literature Review In this study, the aluminium alloy AA6351 was reinforced with TiB2 particles in varying percentages (1, 3, and 5 wt %). The in situ reaction of potassium hexafluoro-titanate and potassium tetrafluoroborate with aluminium melt successfully manufactured the reinforcements. We looked at the composite's hardness, yield strength, and tensile strength. The produced aluminium matrix composites were examined using X-ray diffraction and a scanning electron microscope. TiB2 particles exhibited excellent bonding properties to the aluminium matrix. For a given temperature, the AMCs cause a high level of wear resistance. In order to establish the amount of relevance of the cutting parameters, AA6351, which is reinforced with 5% SiC and 5% B4C, was subjected to a continuous turning process using a PCD tool. An analysis of variance was then performed [2]. The experimental findings showed that the rate of material removal rises as the feed rate and depth of cut are increased. Cutting speeds were discovered to have an effect on power consumption. At slower cutting speeds, the surface roughness was minimal; but, as the feed rate and depth of cut were raised, the roughness began to rise. Since the Ra was minimal under conditions of low cutting speed but rose under those of high feed rate and DOC, cutting speed was determined to be the most important component in determining Ra. In the current study, an aluminium alloy AA6351 was fortified with varying amounts of TiB2 particles (0, 4, and 8 wt %). These particles were successfully created through an exothermic reaction between molten aluminium and inorganic salts, specifically potassium hexafluoro-titanate 201 Journal of Engineering, Mechanics and Architecture www. grnjournal.us and potassium tetrafluoro-borate. The result was an alloy with exceptional properties. We looked at the composite's microhardness, yield strength, compression strength, microhardness, and tensile strength. Optical microscopy, scanning electron microscopy, and X-ray diffraction were used to characterise the generated aluminium matrix composites. A higher mass percentage of titanium diboride particles is associated with a steady improvement in hardness, tensile strength, yield strength, and compression strength. In [4], the hybrid materials Al2O3 and Gr are used to strengthen AA6351 in the production process. Researchers looked at the mechanical behaviour and microstructure of the source alloy as well as the composites made from it. The study examines the reinforcing effect of Al2O3/Gr mixed with the parent alloy, specifically looking at the macro and microhardness levels as well as the tensile and flexural strengths. It was necessary to modify an optical microscope in order to describe the composites. As the reinforcement content in the AA6351 base matrix alloy increases, the hardness, tensile strength, and flexural strength all show positive trends. Dispersing Al2O3/Gr particles into the AA6351 alloy greatly improves its mechanical characteristics. Reinforcement has a linear relationship with the composite's hardness and tensile strength. The aluminium alloy AA6351 is combined with AL2O3 metal to create a composite material using the stir casting method. The material is then examined under a scanning electron microscope to determine its microstructure, hardness, and toughness strength value. The results demonstrate that the composite material's hardness and tensile strength are higher than those of the plain material. However, the toughness value is lower than the plain material's because of the interference of the brittleness between the alloy AA6351 and AL2O3. Research Cap We learn by reviewing the academic journals that nobody has discovered the AA6351/TiB2 material's circularity. Most of the time, they have discovered the material's hardness microstructural characterisation; other times, they have discovered the material's circularity or its turning behaviour. Physical and Chemical Properties of Aluminum Soft, silvery, and relatively light, aluminium is a metal. Due to its high reactivity, an oxide layer, which is both thin and protective, quickly forms in the environment. Its resistance to corrosion is a result of this. Anodizing, an electrolytic oxidation procedure, is a particular treatment that can further improve and increase corrosion resistance of the oxide-protected aluminium surface [43- 49]. Strong reactions between hydrochloric acid and caustic soda occur with aluminium. Contact with cold nitric acid renders it passive, and the reaction with sulfuric acid is weaker. Aluminum has electrical and thermal conductivities that are nearly two-thirds as high as those of pure copper. The element's oxidation number is +3 because of its electrical arrangement, which gives it three valency electrons [50-57]. To improve its qualities, especially its strength, pure aluminium can be chemically combined with other elements to form an alloy. A maximum of fifteen percent of the alloy's weight may come from these additional elements, which include silicon, iron, copper, magnesium, manganese, and zinc. To alloy, these other components must be properly mixed with molten aluminium while the metal is still liquid. Zinc, magnesium, or silicon are some of the components that can alter the qualities of aluminium, including its strength, density, workability, electrical conductivity, and resistance to corrosion [58-65]. 202 Journal of Engineering, Mechanics and Architecture www. grnjournal.us By applying heat or cold working, aluminium alloys can be strengthened. As a result of their processing and additions, the properties of individual alloys vary. To improve its qualities, especially its strength, pure aluminium can be chemically combined with other elements to form an alloy [66-72]. A maximum of fifteen percent of the alloy's weight may come from these additional elements, which include silicon, iron, copper, magnesium, manganese, and zinc. The first digit of an alloy's four-digit number indicates the broad class or series to which it belongs, based on the elements that make up the alloy. Solution heat treatment followed by quenching or fast cooling can strengthen certain alloys. By applying controlled heat, the solid alloyed metal can be heated to a precise temperature. A solid solution is formed when the alloy components, also known as solutes, are evenly dispersed with the aluminium. In order to release the atoms of the solution, the metal is either quickly cooled or quenched. The atoms of the solute then crystallise as a finely dispersed precipitate. Both natural ageing and artificial ageing involve this process, which can take place at room temperature or in a low-temperature furnace [73-81]. Cold working is a way to strengthen alloys that have not been heated. Metal is "worked" to increase its strength during cold working, which happens during rolling or forging processes. For instance, as aluminium is rolled to narrower gauges, its strength increases [82-89]. This occurs because atoms are unable to move relative to each other when dislocations and vacancies are built up in the structure during cold working. The metal's strength is enhanced as a result. Adding alloying elements such as magnesium enhances this action, leading to an even greater increase in strength. The US adopted the wrought alloy naming system in 1954, which was devised almost 60 years before by the Aluminum Association's Technical Committee on Product Standards (TCPS) [90- 96]. The American National Standard H35.1 was accepted three years after the system was developed. This system of naming became officially international in 1970 when the International Signatories of the Declaration of Accord formally endorsed it. That same year, the Association was appointed Secretariat for Standards Committee H35 on Aluminum Alloys by the American National Standards Institute (ANSI). From that point on, the Association has been the world's leading aluminium industry standard-setter [97-101]. Current management of the alloy registration system is carried out by the Association's TCPS. It takes from sixty to ninety days to go from registering an alloy to giving it a new classification. In 1954, when the present system was first being established, there were 75 distinct chemical compositions on the list. More than 530 active compositions have been registered so far, and that number is only going up. That exemplifies how adaptable and pervasive aluminium has grown in the contemporary environment [102-111]. As things stand, TiB2 is only used for certain purposes in fields like neutron absorbers, cutting tools, crucibles, impact-resistant armour, and wear- resistant coatings. For the purpose of vapour painting aluminium, evaporation boats make heavy use of TiB2. Because of its wettability, poor solubility in molten aluminium, and strong electrical conductivity, it is an appealing material for the aluminium industry to employ as an inoculant to refine the grain size while casting aluminium alloys. Applying a thin layer of TiB2 to a sturdy and inexpensive substrate makes it resistant to wear and corrosion [112-119]. Casting 203 Journal of Engineering, Mechanics and Architecture www. grnjournal.us A common manufacturing method known as casting involves pouring a liquid substance into a mould with a predetermined shape's hollow hole and then letting it solidify. Ejecting or breaking the hardened component, also called a casting, from the mould completes the process. Materials used for casting typically include metals or a variety of time-setting substances that cure when mixed with two or more components; they include, but are not limited to, clay, concrete, plaster, and epoxy. Complex shapes that would be either expensive or too difficult to manufacture any other way are typically cast. Massive machinery, such as beds for machine tools, propellers for ships, etc [120-127]. Hardness is defined as a material's resistance to persistent indentation. One way to quantify hardness is by looking at how well a material resists localised plastic deformation caused by mechanical indentation or abrasion. For example, metals are noticeably harder than most other materials (e.g. plastics, wood). There are various ways to evaluate hardness, including scratch hardness, indentation hardness, and rebound hardness. This is because macroscopic hardness is typically associated with strong intermolecular interactions, yet the behaviour of solid materials under stress is complicated. These parameters are dependent on the ones mentioned earlier, and they determine the ductility, plasticity, strain, strength, toughness, viscoelasticity, and viscosity hardness [128-135]. Microstructure One kind of microscope that can magnify tiny objects is the optical microscope, which is also called a light microscope. It works by combining visible light with a set of lenses. The optical microscope, the first type of microscope, may have been developed in its current compound form as early as the 17th century. While many sophisticated optical microscope designs strive to enhance sample contrast and resolution, basic models can be exceedingly simple. An object is set up on a stage so that it may be examined up close using a microscope's eyepieces. Stereo microscopes use slightly distinct images to produce a three-dimensional illusion, in contrast to high-power microscopes where both eyepieces normally display the same image. The image is usually captured with a camera (micrograph). There is a wide range of lighting options for the sample. One way to light up a transparent object is from below, while another way is to shine light through (bright field) or around the objective lens to light up a solid object (dark field). One way to find out which way a metal crystal is facing is to utilise polarised light. By drawing attention to minute differences in refractive indices, phase-contrast imaging can boost picture contrast [136- 138]. Typically, a turret is used to install a variety of objective lenses with different magnifications. This allows for easy rotation into position and provides the capacity to zoom in. Due to the limited resolving power of visible light, optical microscopes usually have a maximum magnification power of about 1000x. A compound optical microscope can achieve a total magnification of 1,000× by multiplying the magnification of the eyepiece (say 10x) and the objective lens (say 100x). Magnification can be enhanced by manipulating the surrounding environment using substances like oil or ultraviolet light. Scanning probe microscopy, optical microscopy, and transmission electron microscopy are alternatives to optical microscopy that do not require visible light and can thus attain far higher magnifications. Many fields rely on optical microscopy, including microbiology, geology, nanophysics, biotechnology, pharmaceutical research, and microelectronics. When testing tissues, free cells, or tissue fragments using smears, optical microscopy is employed; this area of study is known as histopathology. 204 Journal of Engineering, Mechanics and Architecture www. grnjournal.us Industrial settings often make use of binocular microscopes. In addition to helping with tasks that require accurate depth perception, dual eyepieces alleviate the strain on the eyes caused by prolonged periods spent working at a microscopy station. A long-focus or long-working-distance microscope could be useful in some situations. It may be necessary to look at an object through a window, or there may be industrial issues that could be a threat to the goal. These optics are like close-focus telescopes. Accurate measurement is accomplished with the use of measuring microscopes. In general, there are two kinds. To measure distances in the focus plane, one uses a graded reticle. The second, more antique variety allows the user to position the object in relation to the microscope using a micrometre mechanism and basic crosshairs. When using transmitted light at extremely high magnifications, point objects appear as fuzzy discs encircled by diffraction rings. A name for this is Airy discs. The capacity to differentiate between two closely spaced Airy discs is considered the resolving power of a microscope (or, in other words, the ability of the microscope to reveal adjacent structural detail as distinct and separate). Resolving fine details is hindered by these diffraction consequences. The quantity and size of the diffraction patterns are impacted by the objective lens's numerical aperture (NA), the refractive materials utilised in its construction, and the wavelength of light (λ). Therefore, there is a limit, the diffraction limit, beyond which distinct points in the objective field cannot be resolved. One aspect of surface texture is surface roughness, commonly abbreviated as roughness. A real surface's normal vector deviates from its ideal form, which quantifies it. A smooth surface has very slight variations, whereas a rough surface has quite substantial ones. Roughness is the high- frequency, short-wavelength component of a surface's measurable properties in surface metrology. To verify a surface's suitability for a given task, however, it is frequently required to know both the amplitude and the frequency. A physical object's interaction with its surroundings is defined by its roughness. Rough surfaces typically exhibit higher friction coefficients and wear more rapidly than smooth surfaces, according to tribology. Since surface irregularities can serve as crack or corrosion nucleation sites, roughness is frequently a reliable indicator of a mechanical component's performance. Roughness, however, might encourage adherence. When it comes to surface mechanical interactions, such static friction and contact stiffness, cross-scale descriptors like surface fractality tend to be more useful than scale-specific ones. In manufacturing, controlling a high roughness value can be both difficult and expensive, despite the fact that it is generally unwanted. For instance, it's neither easy or cheap to control the surface roughness of components made using fused deposition modelling (FDM). It is common practise to raise the production cost of a surface by smoothing it out. The manufacturing cost and application performance of a component are typically compromised as a result. A roughness measuring device is necessary because the individual inconsistencies in roughness are too tiny to be seen to the human eye. The surface is traversed by a tiny stylus at a consistent speed for a predetermined distance. Obtaining and amplifying an electrical signal allows for a much increased vertical magnification. Numerical values that describe the surface texture may be shown on graphs and screen outputs from this signal. A conical stylus with a spherical tip and a 2μm radius is the norm for roughness measurements according to ISO. To make full use of this tiny stylus, though, you'll need an instrument with superior mechanical qualities. Function/Working Principle of Surface Roughness 205 Journal of Engineering, Mechanics and Architecture www. grnjournal.us For example, in many contexts, the sealing or wear characteristics of two surfaces are impacted by their roughness when they are in close proximity to one another and are in constant motion. Although it may seem like a matter of "the smoother, the better" at first glance, there are often other elements at play that make this statement inaccurate. Rough valleys are necessary for lubrication because they retain oil. We must also take the cost into account; producing extremely smooth surfaces is an expensive endeavour, and this activity might significantly increase the bill without much improving performance. Lubricating two surfaces that are in relative motion (such a shaft and its bearing) does not completely prevent wear. As the peaks fade, any rough surfaces will gradually smooth off. Due to the metal removal, the two pieces' fit will be altered more rapidly than if the finish had been optimal from the beginning. Clamping devices and pins with "interference fits" rely on friction to do their jobs. The use of lip seals to stop the leakage of hydraulic fluids is another example of an application where roughness might affect performance. A fluid layer between the shaft and the seal can be difficult to maintain if the finish is very smooth. Too rough of a finish can abrade the material, which can lead to disintegration and eventual failure. It is common to find tool faults, improper tool settings, speeds, and feeds while inspecting the texture left on a component after machining. A surface's aesthetic value is not always zero. As an example, the sheet steel utilised for vehicle bodies needs a specific type of finish that enables paint to adhere evenly and without a noticeable "orange peel" effect. The challenge of achieving a strong bonded finish is well-known to anybody who has attempted to paint onto glass. Components made of paper and plastic require the same level of repeatability as components made of metal. A profilometer is a tool for quantifying surface roughness by measuring its profile. Surface topography is used to calculate critical dimensions like step, curvature, and flatness. Many non-contact profilometry approaches are challenging the traditional idea of a profilometer as a phonograph-like instrument that moves a surface relative to its own stylus to measure its surface area. Thanks to non-scanning technology, XYZ scanning is unnecessary for measuring surface topography during a single camera capture. Consequently, topographical changes may be monitored in real time. Modern profilometers are characterised as time-resolved profilometers, and they can measure both static and dynamic topography. Circularity To see how near an item should be to a real circle, look for the circularity sign. The two- dimensional tolerance known as circularity regulates the general shape of a circle, making sure it is not excessively oblong, square, or out of round. It is also termed roundness. Regardless of the datum characteristic, roundness is always smaller than the part's diameter dimensional tolerance. The definition of circularity involves taking a cross-section of a spherical or cylindrical object and checking to see if the resulting circle is spherical. Every point on the surface of a circle must fall inside one of two concentric circles. A plane perpendicular to the centre axis of the circular feature lays the tolerance zone (Figure 1). 206 Journal of Engineering, Mechanics and Architecture www. grnjournal.us Figure 1: Two concentric circles Constricting and spinning apart along the central axis measures circularity, while a height gauge records surface change. In two dimensions, circularity is equivalent to cylindricity. When it comes to cylinders, cylindricity makes sure that every point is within a certain tolerance, but when it comes to circles, circularity is all about individual measurements around a single circle. Circumference refers to the area surrounding a single coin in a stack of coins, whereas cylindricity requires the measurement of the complete stack. (the property of being both circular and straight is known as cylindricity). A common measurement used in many areas of production is circularity. When a component, like a bearing or a rotating shaft, must be completely spherical, circularity is typically mentioned. Mechanical engineering drawings frequently feature this GD&T sign. When computing a statistical tolerance stack, circularity—which defines the shape of the surface in a given area—must be taken into account. Assume, for the sake of argument, that you possess a component that bears a marked circularity and diameter. Since geometric tolerance might add to a bigger part envelope than diameter tolerance alone, you'll need to include both in your statistical stack. Since components are seldom exactly round, this should be taken into account, since it will slightly distort the statistical tolerance. Results and Discussion Images of AA651 MMCs with 5% and 10% TiB2 concentrations, respectively, captured electronically. The micrographs show that the TiB2 particles are evenly distributed throughout the matrix alloy and that the typical casting flaws such porosity, shrinkages, and cracks are not present. In order to improve the mechanical properties of composites, it is necessary to have reinforcing particles distributed evenly. According to the measured hardness, the AA6351 MMCs are somewhat harder than the pain aluminium AA6351. The result of Vicker's hardness test was used to determine the hardness value (Table 1). An essential process response that determines the machinability of the component is the Ra. A reduced MRR during machining is required if surface finish is the primary turning criterion. An uneven profile, increased likelihood of ovality, etc., might result from a higher MRR (Figures 2 to 5). Figure 2: Pressure: 190 ; Ra : 1.198 207 Journal of Engineering, Mechanics and Architecture www. grnjournal.us Figure 3: Pressure : 210 ; Ra – 1.246 Figure 4: Pressure : 230 : Ra ; 1.502 Figure 5: Pressure: 150; Ra = 2.064 208 Journal of Engineering, Mechanics and Architecture www. grnjournal.us Figure 6: Pressure 190; Ra: 1.198 Figure 6 shows that surface roughness is high at pressure 190, and the respective surface roughness value was Ra: 1.198. Table 1: AA6351/ 5 wt. % TiB2 Cu Composites S.No Hole No Out of Roundness OR = L1+L2+L3 Difference between upper and lower diameter (Du-DL) 1 170 1.335 +0.178 2 190 1.275 +0.223 3 210 1.349 +0.233 4 230 1.402 + 0.245 5 250 1.455 +0.265 Conclusion Photos taken with an optical camera of AA651 MMCs that contain either 5 percent or 10 percent of TiB2 were taken. In addition to revealing the homogenous distribution of TiB2 particles across the whole matrix alloy, the micrographs do not contain any of the typical casting defects that are common, such as porosity, shrinkages, or cracks. In order to improve the mechanical properties of composites, it is necessary to have reinforcing particles distributed in a homogeneous manner. In comparison to the pain aluminium AA6351, the hardness value that was obtained demonstrates that the AA6351 MMCs have a gradually increasing hardness value. In order to determine the value of the hardness, the Vicker's hardness test was utilised (Table 1). For the purpose of determining the quality of the component that is to be machined, the Ra is an essential process response. The material must be machined with a lower MRR if the surface finish is the primary requirement for turning its surface. Having a higher MRR can result in an uneven profile, an increased likelihood of ovality, and other issues. References 1. V. 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