final review

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Design and Fabrication of Wear Test Specimen Die
for Metal Matrix Composite Materials
MINI PROJECT REPORT
Submitted by
M. Sathish Kannan (120021601163)
K.M.S Shaik Abdul Kader (120021601175)
S. Yashik Imraan (120021601206)
Under the guidance of
Mr. P. DINESH M.E.,
in partial fulfillment for the award of the degree
of
BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING
December 2015

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BONA FIDE CERTIFICATE
Certified that this minor project report “Design and fabrication of wear test
specimen die for metal matrix composite materials” is the bona fide work of
M. Sathish Kannan-120021601166
K.M.S Shaik Abdul Kader-120021601175
S. Yashik Imraan-120021601206
who carried out the project work under my supervision. Certified further, that to
the best of my knowledge the work reported herein does not form part of any
other project report or dissertation on the basis of which a degree or award was
conferred on an earlier occasion on this or any other candidate.
Dr. R.RAJARAMAN Mr. P. DINESH M.E.,
PROFESSOR&HEAD PROJECT GUIDE
Department of mechanical engg. Assistant Professor
B.S Abdur Rahman University Department of mechanical engg.
Vandalur, Chennai-600 048 B.S. Abdur Rahman University
Vandalur, Chennai – 600 048

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ACKNOWLEDGEMENT
First and foremost, we submit our heartfelt thanks to our beloved Chancellor Late
Alhaj. B. S. Abdur Rahman, for having given a wonderful university with state of
art facilities and infrastructure that always promotes fresh flow of ideas and
encourages the learning process.
We sincerely wish to express our gratitude to Dr. V. M. Periasamy, Pro-Vice
Chancellor, B. S. Abdur Rahman University, Chennai. For providing an excellent and
calm atmosphere to carry out this project work.
We would like to thank, Dr. V.Murugesan, Registrar, B. S. Abdur Rahman
University, Chennai for having shared his thoughts and valuable suggestions for the
betterment and completion of the project.
We wish to acknowledge our indebtedness to Dr. M. Murugan, Dean, Department of
Mechanical Engineering, B. S. Abdur Rahman University, Chennai, for his continued
guidance and encouragement for the successful completion for this project work.
We are extremely thankful to Mr. R. Rajaraman, Professor and head, Department of
Mechanical Engineering, B. S. Abdur Rahman University, Chennai for providing us
with valuable guidance and ideas for completing this project work in time
We express our sincere gratitude to Dr. R. Rajendran, Professor, Department of
Mechanical Engineering, B. S. Abdur Rahman University, Chennai, for his kind
encouragement and support during the course of our project work. .
We feel immense pleasure in expressing our thanks and gratitude to our project guide
Mr. P. Dinesh, Assistant Professor, Department of Mechanical Engineering, B. S.
Abdur Rahman University, Chennai, for the inspiration and help, he replenished
throughout the progress of the project work.
We would like to thank Mr. Rathna Raj, Managing Director, Raini Industries,
Ekkaduthangal, Chennai, for having helped to carry out the project at his work shop,
for providing required machineries, time & energy.

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Abstract
Over the past two decades the intrusion of metal matrix composite in the
field of science has made a tremendous growth. The worldwide MMC markets
in 2010 accounted for 250,000 metric tons valued at over $10B. Important
MMC applications in the ground transportation (auto and rail), thermal
management, aerospace, industrial, recreational and infrastructure industries
have been enabled by functional properties that include high structural
efficiency, excellent wear resistance, and attractive thermal and electrical
characteristics. A suite of challenging technical issues has been overcome,
including affordable primary and secondary processing, material design and
development methodologies, and characterization and control of interfacial
properties. In our study we are going discuss about the wear behavior of
Aluminum Nano titanium (MMC) and Aluminum metal wear behavior and
compare both results. In the first phase of our study we have prepared a die for
making Aluminum Nano titanium (MMC) sample specimens for the study
purpose.MMC applications in the major markets of ground transportation,
thermal management, aerospace, industrial, recreational and infrastructure will
be described. Successful commercialization strategies will be discussed and
insights for achieving expanded MMC applications will be given.

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TABLE OF CONTENTS
Chapter No TITLE Page No
Acknowledgement 3
Abstract 4
List of Tables 7
List of Figures 7
1 Introduction. 8
2 Equipment for Wear Testing. 8
3 Die specification. 10
3.1 Low pressure die casting 10
4 Test specimen dimension 11
5 Die casting methods 12
6 Material selection 13
6.1 Oil hardened Non shrinking steel 13
6.2 Composition of OHNS 14
6.3 Properties of OHNS 15
7 Design process 15
7.1 Component design in NX8 software 15
8 Manufacturing process 16
8.1 Low pressure die casting 17

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8.2 Moulding 17
8.3 Conventional shaping process 18
8.4 Surface grinding operation 19
8.5 CNC operation. 20
8.6 Electric Discharge Machining (EDM) 20
8.7 Machining copper electrode for EDM 20
8.8 photograph of wear test die 24
9 Cost estimation 23
9.1 bill of materials 24
10 Result and conclusion 25
11 Reference 26

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List of tables
Table No Description Page No.
6.1 Composition on OHNS 13
6.2 Physical properties of OHNS 15
8.1 Machining process of copper electrode 22
9.1 Bill of materials 24
List of figures
Figure No Description Page No.
Figure 2.1 Pin on disc apparatus 9
Figure 3.1 Die diagram-CADD model 10
Figure 4.1 Test specimen dimension 11
Figure 4.2 Casted OHNS 16
Figure 8.1 Cupola furnace 17
Figure 8.2 Conventional shaping m/c 18
Figure 8.3 Surface grinding m/c 18
Figure 8.4 Vertical milling center 20
Figure 8.6 Schematic working of EDM process 21
Figure 8.7 EDM machining 21
Figure 8.8 Wear test specimen 23

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Chapter -1
Introduction
Wear is nothing but removal of material due to any frictional force.
Wear testing is a method for assessing erosion or sideways displacement of
material from its “derivative” and original position on a solid surface performed
by the action of another surface. This test is commonly used as a simple
measure of workability of material in service. Materials behave differently in
friction state so it may be important to perform mechanical tests which simulate
the condition the material will experience in actual use. A standard result review
for wear tests, defined 52 by the ASTM standards should be expressed as loss of
material during wear in terms of volume. The volume loss gives a truer picture
than weight loss, particularly when comparing the wear resistance properties of
materials with large differences in density.
Chapter-2
Some equipment for wear testing are,
 Pin-on-disc-apparatus.
 Abrasive and adhesive test equipment.
 Pin-on-drum abrasive wear test.
 Repeated impact wear test.
 Adhesion tests using acoustic emission monitoring.
 Block-on-ring test. Etc..

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From so many research journals published Pin-on-disc apparatus was seemed to
be very easy, feasible and reliable equipment for wear testing. Therefore we are
going with it.
The Pin on Disc wear Apparatus consists of a steel disc whose top surface is
case hardened and ground. The disc is rotated by a single ph. Induction motor at
3 different speeds. The test pin is inserted in a pin guide so that one end of pin
touches the rotating disc. The pin guide is mounted on a cantilever to which
spring balance is attached. The pin is inserted in the pin guide. The disc is set to
rotate at the required speed. The required load is put over the pin and wear of
the pin is measured for a time interval of 5 minutes. Different materials can be
tested at different speeds, bearing pressures and either lubricated or non
lubricated form. They figure 2.1 shows the Pin on disc apparatus
Figure 2.1 pin on disc apparatus

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Chapter -3
DIE DIAGRAM
Figure 3.1 Die has been designed using NX8 software
The figure above shows the die design diagram which was designed using NX8
software. The above figure 3.1 shows the all 4 views (top,front,side views & 3D
view) of the die.
DIE SPECIFICATION
Length of die = 125mm
Breadth of die = 112mm
Thickness of die = 44mm
Weight of die = 15 kg (approx..)
Diameter of guide pillar =12mm

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Chapter-4
TEST SPECIMEN DIMENSIONS :
Figure 4.1 model specimen for wear test
The test specimens were prepared based on ASTM G95-99 Standards.
Specimen length = 30mm
Specimen diameter = 10mm
Specimen thickness = 10mm
Reference: ASTM 95-99 standards Test Method for wear Properties of
metal Matrix Composite Materials.
Specimen Diagram:
Figure 4.2 Wear test specimen diagram

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Chapter -5
DIE CASTING METHODS
It is very important that we select an appropriate die casting method.
there are different types of die casting,
 Squeeze die casting.
 Semi-solid die casting.
 Low pressure die casting(LPDC)/low pressure gravity casting(LPCG).
 Vacuum die casting.
For this material we are going to select low pressure die casting.
Low pressure casting is a development of the permanent mould process, in
which the metal is introduced into the chill mould from below. Gas pressure
holds the metal in the die until it solidifies. As with high pressure diecasting the
process requires complex machinery. It is repetitive, and may be automated.
Production rates are fair, but not as good as high pressure. Minimum wall
thickness' are as little as 2-3mm. It has high yields of over 90%, as runners and
risers are excluded, also reducing fettling and trimming costs. Pore-free castings
are obtainable. Machine size will limit the size of castings. Surface finishing
and minimum wall thickness' are both better than gravity die casting, but poorer
than high pressure die casting.
This is a repetitive process where identical parts are cast by injecting molten
metal under low pressure into metal dies. This process requires complex
machinery and is similar to high pressure diecasting.

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Chapter -6
Material Selection
Two materials have to be selected appropriately based on the given application
for forming and machining the work piece. The two materials are selected for,
One for die casting (base die) other material is used for EDM (electric
discharge machining) as a copper electrode for obtaining sharp edges and good
surface finish.
 The Die material is Chosen to be Oil Hardened Non shrinking Steel
(OHNS) because
 OHNS tool steel is very hard and used in many application of
automobile industry, aerospace industry specifically it is used in
dies used for cutting, blanking, piercing, and extrusion operations.
 An ideal type oil-hardened steel which is economical and
dependable for gauging, cutting and blanking tools as well as can
be relied for hardness and good cutting performance.
 O1 Tool Steel is an electric-furnace melted, oil-hardened, non-
shrinking, general-purpose tool steel. It is chemically composed of
approximately.
ELEMENT COMPOSTION
Carbon (C) 0.95%
Manganese(Mg) 1.1%
Chromium(Cr) 0.6%
Tungsten (W) 0.6%

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Vanadium (V) 0.1%
Table6.1 composition of OHNS
The above table shows the chemical composition of oil hardened non shrinking
steel.
 The hardening temperature of O1 tool steel is between 790 degrees
Celsius and 820 degrees Celsius
 It also has a low hardening temperature, and does not lose shape
during quenching. It is inexpensive and readily available.
 In EDM process sharp corners or profile will be achieved by using copper
electrode.
 Copper electrode is used for getting better surface finish.
 While we machine on the edges of the work piece there will be
burrs, to avoid that we use EDM to get rid of those burrs on the
edges of the work piece.
 The copper electrode is machined based on the dimension and
shape of the work piece.
 Edge machining and sharp corners are possible in EDM.
The following table shows the physical properties of OHNS
Max hardness 180-220 bhn (brinell hardness number)
Heat resistance Low
Wear resistance Medium
Machinability Good
Deforming during hardening Medium

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Hardening temperature 760-870 °c
Resistance to decarburization Good
Micro hardness 280 vhn (Vickers hardness number)
Density 8670kg/m3
Emissivity 0.8
Table 6.2 physical properties of OHNS
Chapter -7
Design process
Component diagram for wear test is obtained from ASTM standards G95-99.
 The component diagram is sketched in NX8
 The 2D diagram is converted to 3D diagram by using various commands
 The entire volume is expanded by 0.05% due to compensation of
aluminium shrinkage. Different metals have different shrinkage ratios, to
compensate that shrinkage the cavity’s volume is made slightly larger
than the component.
 The next is the design of the mould cavity, for designing the same
software is used.
 The mould cavity consists of two parts, each is the reflection of the other,
since it is a split pattern(male and female dies).
 Based on the design calculations the mould cavity is designed.
 Both the plates are assembled using assembly commands
 The next step is the purchase of raw material based on the design and
start the manufacturing process

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Chapter - 8
Manufacturing processes
Here we are going to discuss about the manufacturing process which carried out
in preparation of die in a sequential and detailed manner.
There are five Major operations to be carried out for machining the given
workpiece. They are,
 CNC operation.
 Electro discharge machining operation.
 Conventional machining operation.(i,e) Surface grinding
operation, Milling operation and turning operation.
 First the raw material (i,e) Oil Hardened Non shrinking Steel) generally
known as tool steel is procured in adequate amount and the casting
process is done by low pressure die casting (LPDC) using the molten
mould that is obtained from cupola furnace.
Figure 8.1 Casted OHNS

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 The die is designed for Low Pressure Gravity Casting (LPCG) or Low
Pressure Die Casting (LPDC).
 Low-pressure die casting is a process best suited for
aluminium components that are symmetric around an axis of
rotation. Vehicle wheels, for example, are often fabricated
through low-pressure die casting. In this type of process, the
mould is situated vertically above the molten metal bath and
connected via a riser tube. When the chamber is pressurized
(usually between 20 and
100kPa), the metal is pulled upward and into the mould. The
elimination of feeders from this type of die casting process
delivers the high casting yields.
 Cost effective for small scale production
Figure 8.2 cupola furnace.

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Cupola furnace is a melting device used in foundries that can be used to melt
cast iron,ni-resist iron and some bronzes. The cupola can be made almost any
practical size. The size of a cupola is expressed in diameters and can range from
1.5 to 13 feet (0.5 to 4.0 m). The overall shape is cylindrical and the equipment
is arranged vertically, usually supported by four legs. The overall look is similar
to a large smokestack. The above figure 8.2 shows the picture of cupola furnace
The bottom of the cylinder is fitted with doors which swing down and out to
'drop bottom'. The top where gases escape can be open or fitted with a cap to
prevent rain from entering the cupola. To control emissions a cupola may be
fitted with a cap that is designed to pull the gases into a device to cool the gases
and remove particulate matter.
 Now, the raw material sizing is done using a shaping machine.
Figure8.3 Conventional shaping machine
 The shaping machine is used to machine flat metal
surfaces especially where a large amount of metal has to
be removed. Figure 8.3 shows the picture of shaping
machine .Other machines such as milling machines are

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much more expensive and are more suited to removing
smaller amounts of metal, very accurately.
 The surface of the work piece will be uneven after the shaping
operation is completed to obtain a even surface,surface
grinding operation is done using a surface grinding machine to
size down the block to required dimensions. The figure 8.4
shows the picture of a surface grinding machine
Figure8.4 Surface grinding machine
 Now after this process is completed smooth surface is obtained in the
surfaces of the work piece.
 In vertical milling Centre(VMC)- CNC machining is done for the profile
and the runner. The below figure 8.5 shows the picture of vertical
milling center machine

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Figure8.5 Vertical milling center
Electric Discharge machining (EDM)
Electrical Discharge Machining (EDM) is a controlled metal-removal process
that is used to remove metal by means of electric spark erosion. In this process
an electric spark is used as the cutting tool to cut (erode) the work piece to
produce the finished part to the desired shape. Figure below shows the working
principle and circuit diagram of EDM
 EDM has application capability in a large number of industrial areas like
automotive industry, in die and mould making industries, aerospace,
aeronautics and nuclear industries.

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Figure 8.6 schematic working of EDM
Figure 8.7 EDM machining
 The main advantage of EDM is that the tool and the work piece do not
come into contact with each other, hence eliminates chatter and vibration
problems and also allows tiny or thin components to be machined without
mechanical force.

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 Although the metal removal is due to thermal effect, but there is no
heating of bulk material.
 In EDM process sharp corners or profile will be achieved by using copper
electrode.
 Copper electrode is used for getting better surface finish.
 While we machine on the edges of the work piece there will be small
marks, to avoid that we use EDM to get rid of those marks on the edges
of the work piece.
 The copper electrode is machined based on the dimension and shape of
the workpiece,
Round workpiece Square/rectangle
workpiece
Engine lathe/conventional
lathe machine.
Milling machine.
Table 8.1 machining the copper electrode
 Guide pin & bush poles is provided by digital read out
(DRO) milling machine.
 Guide pin is made using lathe and cylindrical grinding
machine.
 Profile is polished manually by using abrasive emery sheet & abrasive
stone.

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Photograph of Wear Test die
Figure 8.8 Both male and female die for wear test.
Chapter- 9
Cost estimation
Bill of materials
PROCESS MATERIAL/MACHINING Rs/KG
Total
cost
MATERIAL OHNS and copper (minimum
quantity)
Rs.130/kg
for 25 kg
3250

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MACHINING Electric discharge machining
2 hours on
the basis of
Rs.75/hour
150
Casting including the raw
material moulding in cupola
furnace
6 hours on
the basis of
Rs. 65/hour
390
CNC machining
1 hour on
the basis of
100/hour
100
LABOUR Electric discharge machining
2 hours on
the basis of
75/hour.
150
Casting including the raw
material moulding in cupola
furnace
6 hours on
the basis of
Rs.100/hour
600
CNC machining 1 hour on
the basis of
100/hour
100
MISCELLANEOUS
EXPENSES
DIE handling and transportation
charges
900 900
Total cost Rs.5640
Table 9.1 bill of materials

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Chapter -10
Conclusion and Result
During the first phase of our project work we have designed and fabricated the
wear test die successfully using OHNS as a die material and various machining
operations (shaping,milling,surface grinding,EDM,CNC operations) were
involved and the mould cavity inside the die were machined according to
ASTM standard G95-99. We have machined two mould cavities inside our die
(i,e it can hold two test specimen at a time) as per our requirement. And in
future we will continue with pouring the ALUMINIUM MATRIX NANO-
TITANIUM DI OXIDE COMPOSITE molten liquid into the die cavity and
take the test specimens and find out the wear characterization of the MMC with
the help of Pin-on disc apparatus.

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Chapter -11
References
.
 Ho KH, Newman ST (2003) State of the art electrical discharge
machining. Int J Mach Tools Manuf 43:1287–1300
 Kuneida M, Lauwers B, Rajurkar KP, Schumacher BM (2005)
Advancing EDM through fundamental insight into the process. Annals of
CIRP 54(2):599–62
 Jain VK (2004) Advanced machining processes. Allied Publishers, New
Delhi. ISBN 81-7764-294-4
 Intelligent Control of Cupola Melting, E.D. Larsen, Et. All, Lockheed
Martin Idaho Technologies Company, June 1997
 ASTM G99-05(2010), Standard Test Method for Wear Testing with a
Pin-on-Disk Apparatus, ASTM International, West Conshohocken, PA,
2010, www.astm.org DOI: 10.1520/G0099-05R10

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