ABSTRACT

This study investigates the machinability of a novel composite material comprising aluminum matrix reinforced with rice husk ash (RHA) particulates. The growing demand for sustainable materials and the abundance of rice husk ash, an agricultural waste product, have inspired the development of this composite, aiming to enhance the mechanical properties and promote its use in various engineering applications. The machinability of this composite is a critical aspect, as it determines its feasibility for practical applications. This study was carried out to produce and analyse the properties of Aluminium Alloy-Rice Husk Ash composites. Rice husk ash (RHA) with high silica content of up to 97.095% was used for the study with the RHA varied from 0vol% – 30vol% at intervals of 5vol% in the aluminium alloy as reinforcement. The density and some mechanical properties of the composites including tensile strength, impact strength, hardness and fatigue strength were investigated. The results showed that the density of the composite decreases with the percentage increase of reinforcement from 2840.242 kgm-3 for the control sample to 2402.899 kgm-3 for 30vol% RHA. The Ultimate Tensile Strength (UTS) varies from 164.374 MNm-2 at 0% RHA to 176.837 MNm-2 with maximum value at 10% RHA, impact strength values varies from 84.020kJm-2 at 0% RHA to 155.244 kJm-2 with maximum value at 10% RHA, hardness value varies from 70.467 RHV at 0% RHA to 109.367 RHV with maximum value at 25% RHA and fatigue strength varies from 0.224x10⁶cycles to 2.582x10⁶ cycles with maximum cycle at 20% RHA. The results of analysis of variance showed that there are significant differences among the means of each property of the composites at different levels of replacement of the ash addition (P<0.05).

 TABLE OF CONTENTS

Title page                                                                                                                                  i

Certification                                                                                                                              ii                 Approval Page                                                                                                                          iii                                                                                                                             Dedication                                                                                                                                iv

Acknowledgement                                                                                                                    v                  Abstract                                                                                                                                    vi                                                                                                       Table of Contents                                                                                                                     vii                                                                             List of Figures                                                                                                                           ix                                                                                              List of Tables                                                                                                                            x                                                                                                                List of Nomenclature                                                                                                                xi                        List of Abbreviations                                                                                                                xii

CHAPTER ONE:   INTRODUCTION

1.1      Background of the Study                                                                                                    1

1.2      Statement of Research Problem                                                                                         4

1.3      Aim and Objectives of the Research                                                                                  4

1.4      Justification of the research                                                                                                5

1.5      Scope of the Study                                                                                                              5

1.6      Significance of the Study                                                                                                   5

CHAPTER TWO: LITERATURE REVIEW

2.1        Introduction to Aluminium Matrix Composites                                                             6

2.1.1    Fiber Reinforced AMC                                                                                                   7

2.1.2    Fly Ash Reinforced AMC                                                                                              8

2.1.3    Biomass Ash Reinforced AMC                                                                                      9 

2.1.4    Rice Husk as an AMC Reinforcement                                                                         10

2.2      Machinability Studies on Composites and Alloys Using Several Design                    12

           Of Experiment (DOE) Techniques     

 

2.2.1   Mechanics of Chip Formation                                                                           14

2.2.2   Four Basic Types of Chip Formation                                                                             16

2.2.3   Turning                                                                                                                          17

2.2.4    Power and Energy Relationship                                                                                   18

2.2.5    Cutting Parameters in Machining                                                                                 21

2.3      Identified Research Gap                                                                                                22

CHAPTRER THREE: MATERIALS AND METHODS

3.1    Materials                                                                                                                          23

3.1.1   Casting Materials                                                                                                           23

3.1.2   Machining Materials                                                                                                      23

3.1.3   Equipment                                                                                                                      24

3.2.  Method                                                                                                                             25

3.2.1     Preparation of Rice Husk                                                                                             25

3.2.2    Composite Production                                                                                                              25

3.2.3    Design of Experiments                                                                                                 27

CHAPTER FOUR: RESULTS AND DISCUSSION

4.1       Results                                                                                                                         29

4.2      Optimization of the Effect of Cutting Parameters on Surface Roughness                   36

4.3      Regression Equation                                                                                                     40

CHAPTER FIVE: CONCLUSION AND RECOMMENDATIONS

5.1 Conclusions                                                                                                                       42

5.2. Recommendation                                                                                                              43

REFERENCES