Drilling of hybrid Al-5%SiCp-5%B4Cp metal matrix composites

Hybrid metal matrix composites consist of at least three constituents-a metal or an alloy matrix and two reinforcements in various forms, bonded together at the atomic level in the composite. Despite their higher specific properties (properties/unit weight) of strength and stiffness, the nonhomogeneous and anisotropic nature combined with the abrasive reinforcements render their machining difficult. The work piece may get damaged and the cutting tools experience high wear rates, which may lead to an uneconomical production process or even make the process impossible. This work reports on the drilling of Al-5%SiCp-5%B4Cp hybrid composite with high-speed steel (HSS), not expensive PCD, or carbide drills in an attempt to explore the viability of the process. Drilling of Al-5%SiC-5%B4C composites with HSS drills is possible with lower speed and feed combination. The cutting conditions for minimized tool wear and improved surface finish are identified. Characterization of tool wear and surface integrity are also carried out.