Chapter 58

The Role of HBN Solid Lubricant

Reducing Cutting Forces of Dry
Machined Al-B4 C Composite

M. Rajesh , K. Rajkumar , A. Gnanavelbabu and K. M. Nambiraj

Abstract The Aluminum metal matrix composites are known as advanced engineer-
ing materials due to their mechanical and thermal characteristics. The machining of
these materials, as extremely hard, required an intrinsic lubrication to reduce the
cutting forces. The present study focuses on the machining of Aluminum–Boron
carbide composites with the effect of solid lubricant hexagonal boron nitride (hBN).
The machining of composites was done with constant B4 C-5% and hBN varied from
5 to 15%. The machining performance is characterized by cutting force and tool
wear with the effect of feed, speed, and depth of cut. Polycrystalline diamond (PCD)
inserts were used to perform the machining. The composite microstructure shows
that fairly distribution of hBN and boron carbide particles. The increase in the boron
carbide increases hardness obviously. The depth of cut, feed and cutting speed was
correlated to the cutting forces and tool wear. The rate of flank wear was significantly
reduced with hBN particle concentration due to the smearing of these particles in the
cutting zone. The machining forces were also reduced to an extent with increasing
in hBN particles due to covered soft film over the cutting zone.

Keywords hBN · PCD · Tool wear · Cutting force

M. Rajesh
Department of Mechanical Engineering, Prathyusha Engineering College, Thiruvallur 602 025,
India
K. Rajkumar (B)
Department of Mechanical Engineering, SSN College of Engineering, Kalavakkam 603 110, India
e-mail: rajkumark@ssn.edu.in
A. Gnanavelbabu
Department of Industrial Engineering, College of Engineering – Guindy, Anna University,
Chennai 600025, India
K. M. Nambiraj
Department of Mechanical Engineering, Jeppiaar SRR Engineering College, Padur, Chennai 603
103, India

© Springer Nature Singapore Pte Ltd. 2020 697

M. S. Shunmugam and M. Kanthababu (eds.), Advances in Unconventional
Machining and Composites, Lecture Notes on Multidisciplinary
Industrial Engineering, https://doi.org/10.1007/978-981-32-9471-4_58
698 M. Rajesh et al.

58.1 Introduction

The demands made on materials for better overall performance are so great and
diverse that no one material can satisfy them. That naturally leads to a resurgence of
the ancient concept of combining different materials in an integral composite mate-
rial system that result in a better performance. Particle reinforced aluminum matrix
composites are widely used to engineer several parts of automobiles and many other
mechanical and electrical products. This is because of MMC’s extensive engineering
properties such as wear resistance, fracture toughness, good strength, and stability.
The yield strength and modulus are higher for the metal matrix composites [1]. In
complexity lead by High Speed Steel (HSS) and carbide tools when an encounter
with machining MMC composites, due to higher hardness reinforcing particles and
its abrasive nature, which in many cases, MMC composites are slightly harder than
the commonly used tools [2]. Composite material consists of Al-6061is the matrix
since its lighter and corrosion resistance and easily workable. B4 C as the reinforce-
ment added to the matrix since it has extreme hardness, resistance to chemicals,
excellent nuclear properties. Aluminum 6061-B4 C composite system dispersed with
solid lubricant particles like hexagonal boron nitride (hBN) has been established
as potential engineering materials for a number of antifriction applications [3]. The
role of hBN in such applications is to reduce the friction, wear and cutting force of
materials by forming a tribo-induced layer of hBN on the interacting surfaces. There
is a significant reduction in direct metal-to-metal contact with the presence of hBN
particles [4]. During machining, the hBN particles are smearing between a cutting
tool and work surface due to weak intermolecular force between the hBN layers. The
concentration of hBN influenced the topography of machined surfaces [5].
The major issue preventing wider use of MMCs is their poor machinability. Since
the soft matrix holding together with very hard particulates, however, it possible
to reduce a tendency of abrasive action to cutting tool by an introduction of softly
layered films between them. Polycrystalline diamond tools (PCD) insert is normally
used for machining MMC composites under dry machining conditions [6]. Many
research studies were undertaken for the machining of aluminum composite the
important observation of BUE formation significantly affects the tool wear at low
speeds whereas thermal softening plays important role at higher speeds and feed rates
[7]. The decrease in the amount of hexagonal boron nitride also affects the formation
of built-up edge thus leading to tool wear. The rate of flank wear and cutting force
are high when machining with a higher depth of cut. Increase the feed rate increases
the flank wear and cutting force [8].
In this present study has been carried out to investigate of high speed turning
parameters like cutting speed, feed rate and depth of cut to thrust force of Al-B4 C-
hBN metal matrix composites. Tool selection is very important for machining of metal
matrix composites. Gallab and Sklad [9] showed that the employability of PCD tools
over composite Al2O3 /TiC tools due to higher hardness and thermal conductivity. It
is found that PCD and PCBN tools were much better than WC tools for the MMC
machining. Tomac and Tonnessen [10] experimented that softening of MMC at a
58 The Role of HBN Solid Lubricant Reducing Cutting Forces … 699

higher temperature; causes reinforced particles to plow into the workpiece prevents
rapid tool wear. However, no work addresses the machinability of Al-B4 C-hBN as
hybrid composite produced by stir casting. Hence, the main objective of the present
work is to study the role of hBN and machining parameters.

58.2 Experimental Procedure

58.2.1 Composite Fabrication

The MMC consists of Al 6061 was the base matrix material. Initially, it was subjected
to melting for 90 min in an electric furnace to a temperature of about 740 °C. Then
the reinforcement material B4 C (16–20 µm) and the solid lubricant hexa boron
nitride (<10 µm) mixture were preheated to 250 °C in a muffle furnace and added
to the base matrix. The three-step addition of reinforcement process is carried out to
avoid agglomeration and better distribution of microparticles. This mixture is then
subjected to stirring at the rate of 90 rpm for 20 min. This is done so that there
is sufficient dispersion of the B4 C and hBN. The molten slurry was poured into
the mold; the mold was preheated so that fast cooling of the melt can be avoided.
The mold’s dimensions are 22 mm inner diameter and 110 mm length. After the
solidification of the MMC, T6 heat treatment process was done. The concentration
of reinforcement’s particles in a matrix is shown in Table 58.1.

58.2.2 Machining

The fabricated composites were turned on a medium-duty lathe with a drive motor
power of 1.5 kW. The cutting parameters such as cutting speed, feed and depth of
cut are taken as the control factors and are listed in Table 58.2. The cutting force was
measured using an IEICOS lathe tool dynamometer with a digital force indicator.
The PCD cutting tool was used to perform machining.
The cutting forces generated during machining are noted. The one factor at a
time-based experimentation work helps to understand the mechanics of cutting force
produced in response to the input process parameter. SEM image analysis is done to
understand the cutting surfaces of composites and tool wear.

Table 58.1 Concentration of

Composition Al B4 C hBN
Al/B4 C/hBN composite in
(vol.%) C1 80 15 5
C2 75 15 10
C3 70 15 15
700 M. Rajesh et al.

Table 58.2 Machining

Cutting parameter Units Levels
parameters
Cutting speed m/min 25, 85
Feed rate mm/rev 0.15, 0.3
Depth of cut Mm 0.2, 0.6
Dry machining

58.3 Results and Discussion

58.3.1 Microstructure of Composite

The uniform distribution of microparticles investigation on fabricated MMC is car-

ried out by SEM image analysis. There is no agglomeration of the reinforcement
particles, any micro cracks, and voids in the MMC, as observed from SEM image of
composites, as depicted in Fig. 58.1. The relative size of boron carbide and hBN parti-
cles are clearly seen from this figure. These reinforcement’s particles were intact with
an aluminum matrix. EDX spectrum shows peaks of aluminum, boron carbide, hBN
particle, and alloying elements thus confirm chemical composition of the composite.

58.3.2 Effect of Cutting Force to Cutting Speed in Minimum

and Maximum Feed and Depth of Cut

Cutting force measurements are quite complex due to composition, size and uniform
distribution of reinforced particles. Anyway measurement of cutting force makes
understanding the concepts of composite machining. Cutting force analysis with
varying cutting speed, feed, and depth of cut are taken for discussion. For every

Fig. 58.1 Typical SEM image with EDX of Al/B4 C/hBN composite microstructure
58 The Role of HBN Solid Lubricant Reducing Cutting Forces … 701

Fig. 58.2 Cutting force versus speed (minimum and maximum feed and depth of cut)

cutting condition, three trails were availed and mean value is taken for better accuracy.
Figure 58.2 shows a variation cutting force with speeds at conditions of feed rate
0.15 mm/rev, depth of cut 0.2 mm and maximum feed rate 0.3 mm/rev and depth of cut
0.6 mm are constant. The cutting speed is much influenced at low concentration hBN
particles due to scarcity solid lubricant particles. The boron carbide particle raises
the cutting forces when interacting with a cutting tool. The cutting force is stabilized
with speed at higher concentration of hBN particles. The general observation is that
the cutting force decrease with increasing cutting speed. A similar observation is
made from the machining experiment. The thrust force decrease as a result of low
shear hBN thin-film covered in the machining area. Moreover, to increase the hBN
particle to decrease the magnitude of cutting force. From the graph it is also observed
that with increase in cutting speed, thermal softening of the aluminum MMC makes
the easier flow of chip and results lower cutting force consumption.

58.3.3 Effect of Cutting Force to Feed Rate in Minimum

and Maximum Speed and Depth of Cut

Figure 58.3 shows a variation cutting force with feed rate at conditions of minimum
speed 25 m/min and depth of cut 0.2 mm and maximum speed 85 m/min and depth of
cut 0.6 mm are constant. From the plot shows is increasing the feed rate to increase the
magnitude of cutting force. This affects the cutting force increases with an increase in
feed rate. The heat generated is also more which increase in feed rate and the generated
heat is mostly carried away by chip and remaining is present in the material. This
may cause micro dimensional changes in the material. Moreover, considering all the
processing parameters the cutting forces decreased with increasing hBN particles in
the matrix. From the graph, it is also plotted that with increase in feed rate cutting
force is also increased. At higher feed rate, cutting temperature is very high due to
702 M. Rajesh et al.

Fig. 58.3 Cutting force versus feed (minimum and maximum speed and depth of cut)

short period of machining the same length and developed cutting temperature cannot
be taken away completely by the chip.

58.3.4 Effect of Cutting Force to Depth of Cut in Minimum

and Maximum Cutting Speed and Feed

Figure 58.4 shows the cutting force to a depth of cut at conditions of minimum cutting
speed 25 m/min and feed rate 0.15 mm and maximum cutting speed 85 m/min and
feed rate 0.3 mm are constant. From the plot, it shows a depth of increase in magnitude
force. This is a cause of more materials removed at the same time. The number of
layers to be removed in a single pass is high with increased depth of cut and relatively
inclusion of abrasive particles (B4 C) in chip removal also very high. This requires

Fig. 58.4 Cutting force versus depth of cut (minimum and maximum speed and feed rate)
58 The Role of HBN Solid Lubricant Reducing Cutting Forces … 703

Fig. 58.5 SEM image of

flank wear for 5% hBN
composite

higher cutting force to remove excess layers of materials. The magnitude of cutting
force is higher when considering the depth of cut with other parameters.

58.3.5 Flank Wear Analysis

Aluminum composite machining is difficult due to the presence of hard particles

inclusion. Though, it is made easier by the addition of self-lubricating powders
(hBN). The tool wear for the turning of the composite was characterized by flank
wear and built-up edge formation. The cutting tool undergoes high stress, cutting
temperature and rubbing action and micro-welding during machining. Both abra-
sive and adhesive wear mechanism stimulates the rapid tool wear at higher cutting
temperature. The SEM image of the worn out PCD insert (at various cutting speed),
is shown in Figs. 58.5 and 58.6. This SEM image shows that occurrence of flank
wear and formation of a built-up edge as in the case of C1 composite. Considering
the built-up edge, hBN reduces the welding of work material over the tool rake sur-
face. Increasing the hBN particles in composite decrease the tool wear as shown in
Fig. 58.6, there is a mild tool wear observed. So, it is evident that hBN reduces the
tool wear.

58.4 Conclusions

The results of turning operation on hybrid metal matrix Al-B4 C-hBN composites
using PCD tool by varying machining parameters were presented. From the results
obtained, the following conclusions can be drawn:
704 M. Rajesh et al.

Fig. 58.6 SEM image of

flank wear for 15% hBN
composite

1. Higher depth of cut and feed rate produces more cutting force.
2. Higher cutting speed with lower depth of cut and lower feed rates develop low
cutting forces.
3. Cutting force reduced by adding hBN due to the formation of low shear strength
thin film on the cutting surface. This is possibly reduced friction between tool
and work during machining.
4. Flank wear of cutting tool reduces with increasing hBN addition which confirmed
by SEM observation.

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