Concurrently, most researches focus on the material preparation process and the mechanical properties of in situ particles reinforced MMCs. However, for engineering applications, adequate knowledge for machining these high performance materials is necessary. It is well known that the reinforcement particles embedded in the matrix are highly abrasive. This makes the machining of MMCs difficult, and the difficulties primarily are rapid tool wear and poor surface quality. Since the preparation process of ex situ MMCs is much easier, SiC particles reinforced MMCs are widely used in industry practice. Hence, most studies have dealt with the machinability of SiC particles reinforced MMCs in tool wear, surface integrity, and chip formation.
On the other hand, very little work has been done on the machining of in situ MMCs. Ding et al. studied the grinding behavior of TiCp/Ti-6Al-4V MMCs (PTMCs). They found that PTMCs are more difficult to remove than Ti-6Al-4V, and low depth of cut and high workpiece speed are beneficial for abetter surface quality. Further, the performance of electroplated CBN wheel and that of brazed CBN wheel were compared, and it was found that brazed CBN wheel has greater potential in high-speed grinding of PTMCs according to experimental results. Anandakrishnan and Mahamani investigated the machinability of in situ Al-6061-TiB2 MMCs. The effects of cutting parameters on tool wear, cutting force and surface roughness were analyzed. The relationship between TiB2 reinforcement ratio and tool wear, surface roughness, and cutting forces were achieved. Senthil et al. studied the machinability characteristics of homogenized Al-Cu/TiB2 in situ metal matrix composites. The effects of parameters on performance measures were investigated during turning operations, and the built-up edge and chip formation were also examined. Sivaet al. developed a new in situ ceramic reinforced aluminum metal matrix composite, and the machinability of this new AMC was investigated by comparing with two other composites made with Al2O3 and Al2O3-SiC. Jiang et al. carried out experimental investigation on the machinability on TiB2/Al MMCs. Tool wear, surface quality, and chip formation were discussed. It was found that PCD tool sustained the least tool wear compared to PCBN and coated-carbide tools. Xiong et al. studied the surface integrity and tool wear mechanisms of TiB2/Al MMCs. The main tool wear mechanisms are abrasion, adhesion, chipping, and peeling wear. Tool life is various from 3 to 20 min for uncoated carbide tools, and milling speed has the dominated influence.
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