Study of machinability and wear Characteristics of polymer ceramic Composites

Abstract

Polymer-ceramic composites are valued for their lightweight, high strength, wear newlineresistance, and thermal stability, making them ideal for aerospace, automotive, marine, newlineand structural applications. However, optimizing their mechanical properties, wear newlineresistance, and machinability remains challenging. newlineThis study develops and characterizes epoxy composites reinforced with Barium Titanate newline(BT) and Calcium Copper Titanate (CCT), using single and hybrid ceramic reinforcements. newlineMechanical tests assess structural performance, while wear behavior is analyzed through newlinesolid particle erosion and dry sliding wear tests, varying impingement angle, particle newlinevelocity, normal load, sliding velocity, and distance. SEM examines wear mechanisms and newlinesurface morphology. newlineFor machinability, Abrasive Jet Machining (AJM) evaluates jet pressure, stand-off newlinedistance, and material type on material removal rate (MRR) and surface roughness (Ra). newlineTaguchi Design of Experiments (DOE) optimizes MRR and Ra, while Grey Relational newlineAnalysis (GRA) ensures balanced machining performance. newlineResults show that hybrid BT-CCT reinforcement significantly enhances mechanical strength, newlinewear resistance, and machinability. Tensile and flexural tests confirm improved stiffness, newlinewhile hardness and impact tests demonstrate resilience. Wear studies reveal erosion newlineresistance depends on impingement angle and particle velocity, while dry sliding wear tests newlineshow ceramic reinforcement reduces frictional degradation. AJM analysis identifies standoff distance and jet pressure as key factors in machining efficiency. newlineBT-CCT epoxy composites are promising for applications requiring wear resistance and newlineprecision machining, such as dry-running bearings, space components, and hightemperature machinery.