Automobile and aero industries have an increasing interestin materials with improved mechanical properties. However, manyof these new materials are classified as difficult-to-cut withconventional tools. It is obvious that tools, cutting processesand cutting models has to be devel-oped parallel to materialsscience. In this thesis rotary cutting tools are tested as analternative toexpensive diamond or cubic bore nitridetools. Metal matrix composites mostly consist of a light metalalloy (such as aluminium or titanium) reinforced with hard andabrasive ceramic parti-cles or fibres. On machining, thereinforcement results in a high rate of tool wear. This is themain problem for the machining of MMCs. Many factors affect thelife length of a tool, i.e. matrix alloy, type, size andfraction of the reinforcement, heat treatment, cuttingconditions and tool properties. In tests, the Al-SiC MMC formed a deformation layer duringmilling, probably affected by lack of cooling. The dominatingfactor for tool life was the cutting speed. Water jet or CO2cooling of turning did not provide dramatic increase in toollife. With PCD, cutting speeds up to 2000 m/min were usedwithout machining problems and BUE formation. Tool flank wearwas abrasive and crater wear created an "orange-peel type" wearsurface. PCD inserts did not show the typical increase in flankwear rate at the end of its lifetime. The use of self-propelled rotary tools seems to be apromising way to increase tool life. No BUE was formed on therotary tool at high cutting data. The measurements indicatethat the rotary tool creates twice as good surface as PCDtools. The longest tool life was gained with an inclinationangle of 10 degrees. Tool costs per component will beapproximately the same, but rotary cutting tool allows higherfeeds and therefore a higher production rate and thus a lowerproduction cost. The rotary cutting operation might have a potential toincrease productiv-ity in bar peeling. The lack of BUE withrotary cutting gives hope on higher tool life. The test resultsshow that tool wear was 27% lower with rotary cutting tools.Increase of cutting speed from 22 to 44 m/min did not affectcutting forces. This indicates that the cutting speed canincrease without significant change in tool wear rate. Issues related to rotary cutting like cutting models,cutting processes, standards, tools and models have beendiscussed. A tool wear model with kinetic energy has beendiscussed. KEYWORDS:Difficult-to-Cut material, Metal MatrixComposite (MMC), Machining, Machinability, Rotary Cutting Tool,Acoustic Emission / <p>QCR 20161026</p>

<p>Automobile and aero industries have an increasing interestin materials with improved mechanical properties. However, manyof these new materials are classified as difficult-to-cut withconventional tools. It is obvious that tools, cutting processesand cutting models has to be devel-oped parallel to materialsscience. In this thesis rotary cutting tools are tested as analternative toexpensive diamond or cubic bore nitridetools.</p><p>Metal matrix composites mostly consist of a light metalalloy (such as aluminium or titanium) reinforced with hard andabrasive ceramic parti-cles or fibres. On machining, thereinforcement results in a high rate of tool wear. This is themain problem for the machining of MMCs. Many factors affect thelife length of a tool, i.e. matrix alloy, type, size andfraction of the reinforcement, heat treatment, cuttingconditions and tool properties.</p><p>In tests, the Al-SiC MMC formed a deformation layer duringmilling, probably affected by lack of cooling. The dominatingfactor for tool life was the cutting speed. Water jet or CO2cooling of turning did not provide dramatic increase in toollife. With PCD, cutting speeds up to 2000 m/min were usedwithout machining problems and BUE formation. Tool flank wearwas abrasive and crater wear created an "orange-peel type" wearsurface. PCD inserts did not show the typical increase in flankwear rate at the end of its lifetime.</p><p>The use of self-propelled rotary tools seems to be apromising way to increase tool life. No BUE was formed on therotary tool at high cutting data. The measurements indicatethat the rotary tool creates twice as good surface as PCDtools. The longest tool life was gained with an inclinationangle of 10 degrees. Tool costs per component will beapproximately the same, but rotary cutting tool allows higherfeeds and therefore a higher production rate and thus a lowerproduction cost.</p><p>The rotary cutting operation might have a potential toincrease productiv-ity in bar peeling. The lack of BUE withrotary cutting gives hope on higher tool life. The test resultsshow that tool wear was 27% lower with rotary cutting tools.Increase of cutting speed from 22 to 44 m/min did not affectcutting forces. This indicates that the cutting speed canincrease without significant change in tool wear rate.</p><p>Issues related to rotary cutting like cutting models,cutting processes, standards, tools and models have beendiscussed. A tool wear model with kinetic energy has beendiscussed.</p><p><b>KEYWORDS:</b>Difficult-to-Cut material, Metal MatrixComposite (MMC), Machining, Machinability, Rotary Cutting Tool,Acoustic Emission</p>

The development of metals that can overcome the strength-ductility-weight trade-off has been an ongoing challenge in engineering for many decades. A promising option for making such materials are Metal matrix composites (MMCs). MMCs contain dispersions of reinforcement in the form of fibers, particles, or platelets that significantly improve their thermal, electrical, or mechanical performance. This dissertation focuses on reinforcement with two-dimensional (2D) materials due to their unprecedented mechanical properties. For instance, compared to steel, the most well-studied 2D material, graphene, is nearly forty times stronger (130 GPa) and five times stiffer (1 TPa). Examples of reinforcement by graphene have achieved increases in strength of 60% due to load transfer at the metal/graphene interface and dislocation blocking by the graphene. However, the superior mechanical properties of graphene are not fully transferred to the matrix in conventional MMCs, a phenomenon known as the "valley of death." In an effort to develop key insight into how the relationships between composite design, processing, structure, properties, and mechanics can be used to more effectively transfer the intrinsic mechanical properties of reinforcements to bulk composite materials, nanolayered composite systems made of Ni, Cu, and NiTi reinforced with graphene or 2D hexagonal boron nitride h-BN is studied using experimental techniques and molecular dynamics (MD) simulations. / Doctor of Philosophy / The design of new metals with concurrently improved strength and ductility has been an enduring goal in engineering for many decades. The utilization of components made with these new materials would reduce the weight of structures without sacrificing their performance. Such materials have the potential to revolutionize many industries, from electronics to aerospace. Traditional methods of improving the properties of metals by thermomechanical processing have approached a point where only minor performance improvements can be achieved. The development of Metal matrix composites (MMCs) is among the best approaches to achieving the strength-ductility goal. Metal matrix composites are a class of materials containing reinforcements of dissimilar materials that significantly improve their thermal conductivity, electrical conductivity, or mechanical performance. Reinforcements are typically in the form of dispersed fibers, particles, or platelets. The ideal reinforcement materials have superior mechanical properties compared to the metal matrix, a high surface area, and a strong interfacial bond with the matrix. Two-dimensional (2D) materials (materials made up of a single to a few layers of ordered atoms) are attractive for reinforcement in composite materials because they possess unprecedented intrinsic properties. The most well-studied 2D material, graphene, is made of a single layer of carbon atoms arranged in a hexagonal honeycomb pattern. It is nearly forty times stronger (130 GPa) and five times stiffer (1 TPa) than steel. Examples of graphene reinforcing have shown increases in strength of 60% due to load transfer at the metal/graphene interface and dislocation blocking by the graphene. Despite their exceptional mechanical properties, the superior mechanical properties of graphene are not fully transferred to the matrix when incorporated into conventional metal matrix composites. This phenomenon, known as the "valley of death," refers to the loss of mechanical performance at different length scales. One cause of this phenomenon is the difficulty of evenly dispersing the reinforcements in the matrix using traditional fabrication techniques. Another is the presence of dislocations in the metal matrix, which cause very large local lattice strains in the graphene. This atomistic-scale deformation at the interface between the metal and the graphene can significantly weaken it, leading to failure at low strains before reaching its intrinsic failure stress and strain. This dissertation aims to provide insight into how the relationships between composites' design, processing, structure, properties, and mechanics can be used to transfer intrinsic mechanical properties of reinforcements to bulk composite materials more effectively. For this, nanolayered composite systems of Ni and Cu reinforced with graphene or 2D h-BN were studied using experimental techniques and molecular dynamics (MD) simulations to elucidate the underlying mechanisms behind the composites' material structure and mechanical behavior. Additionally, we explore the incorporation of graphene in a metallic matrix that does not deform through dislocations (or shear bands), such as the shape memory alloy nickel-titanium ( Nitinol or NiTi), to avoid low strain failure of the metal/graphene interface. This theoretical strengthening mechanism is investigated by designing and fabricating NiTi/graphene composites.

No description available.

No description available.

[pt] O objetivo deste estudo foi desenvolver compósitos à base de uma liga de AlSi (Alumix-231) com adição de 5 a 20 vol. por cento de sílica fundida, no intuito de reduzir o coeficiente de expansão térmica (CET), com relação ao da matriz, e manter as propriedades físicas do compósito, tais como densidade e dureza, ao menos no nível da matriz. Os compósitos foram desenvolvidos pela metalurgia do pó, primeiramente, prensados a 700 MPa e depois sinterizados em temperaturas entre 565 e 575 graus C por 90 min (condição T1). Os melhores resultados, em termos de redução da expansão térmica, foram alcançados após a sinterização a 565 graus C. Os compósitos com adição de 15 e 20 vol.por cento de sílica fundida exibiram coeficientes de expansão térmica tão baixos quanto 13,70 e 12,73 x 10(-6) graus C(-1) (entre 25 e 400 graus C), uma redução de 29,9 por cento e 34,8 por cento, respectivamente, em comparação com Alumix231 pura. Além disso, a densidade e a dureza desses compósitos não foram muito afetadas negativamente, pois sofreram apenas uma pequena diminuição, não superior a 6 por cento e 5 por cento, respectivamente. Em seguida, amostras sinterizadas a 565 graus C foram envelhecidas artificialmente a 160 graus C por 8 h (condição T6) e os Compósitos de Matriz Metálica (CMMs) com 15 e 20 vol. por cento de sílica fundida exibiram um aumento da dureza, cerca de 94,12 por cento e 64,71 por cento, respectivamente, em relação às amostras análogas na condição T1. Com relação à expansão térmica, houve redução dos CETs, em comparação com a liga pura envelhecida, de 27 por cento e de 32 por cento, respectivamente. Alumix-231 é uma nova e promissora liga e a sílica fundida, que nunca foi usada antes com o objetivo de reduzir sua expansão térmica, demonstrou ser uma cerâmica com aplicações promissoras como carga em compósitos de matrizes à base de Alumix-231 devido à sua expansão térmica próxima de zero e à sua baixa densidade. Como tal, os resultados obtidos mostraram que os compósitos de Alumix-231/sílica fundida são materiais potencialmente promissores para aplicações automotivas, candidatos a substituírem o ferro fundido (alta densidade, de 7,3 a 7,9 g cm(-3) , e CET de 13 x 10(-6) graus C(-1)). / [en] The goal of this study was to develop composites based on an Al-Si alloy (Alumix-231) with the addition of 5 to 20 vol. percent of fused silica, to reduce the coefficient of thermal expansion (CTE) in comparison to that of the matrix (Alumix-231), keeping the composite light and without impairing its physical properties, such as density and hardness. The composites were developed by powder metallurgy, first pressed at 700 MPa, and then sintered at temperatures between 565 and 575 degrees C for 90 min (T1 condition). The best results, in terms of reduced thermal expansion, were achieved after liquiq-phase sintering at 565 degrees C. Composites with the addition of 15 and 20 vol. percent of fused silica exhibited CTEs, as low as, 13.70 and 12.73 x 10(-6) degrees C(-1) (between 25 and 400 degrees C), a reduction of 29.9 percent and 34.8 percent, respectively, compared to neat Alumix-231. Furthermore, the density and hardness of these composites were not negatively affected, as these properties presented only a small decrease, not exceeding 6 percent and 5 percent, respectively. Then, samples sintered at 565 degrees C were artificially aged at 160 degrees C for 8 h (T6 condition), and MMCs-15 and 20 vol. percent exhibited an increase in hardness of about 94,12, percent and 64,71 percent, compared to T1 samples. Regarding thermal expansion, there was a reduction of CTEs, compared to the aged neat alloy, of 27 percent and 32 percent, respectively. Alumix-231 is a promising new alloy and fused silica, which has never been used before to reduce its thermal expansion, has shown to be a ceramic with promising applications as a filler in Alumix-231-based matrix composites, due to its thermal expansion close to zero. As such, the results obtained showed that Alumix231/fused silica composites are promising materials for automotive applications and new candidates to replace heavy cast iron components.