Issues in machining epoxy resin - nano reinforcement composite systems with respect to surface integrity and tool wear

Polymer nanocomposites, reinforced with nanoparticles such as SiO2, are gaining attention due to their improved mechanical properties.However, the impact of SiO2 nanoparticle content on machining processes, particularly tool wear and surface quality, remains insufficiently explored.This study investigates the effect of different SiO2 concentrations (0-8 wt.%) on tool wear (VB), surface roughness (Ra), and chip formation during the micromachining of epoxy-based composites.Samples were fabricated with varying SiO2 content and machined using a micro-milling process.The tool wear and surface roughness were evaluated at regular intervals, with the wear predominantly occurring within the first few minutes of cutting.Results show that as the SiO2 content increases, tool wear accelerates, leading to higher surface roughness.In particular, the addition of SiO2 contributed to the formation of non-dispersed clusters, which exacerbated tool wear.The chip morphology shifted from worm-like to crumbly as tool wear increased, reflecting the progressive degradation of the machining process.These findings suggest that while higher nanofiller content may improve material strength, it significantly impacts the machining efficiency and surface quality, particularly when filler dispersion is poor.The study highlights the importance of optimizing the dispersion of nanofillers to maintain machining stability and surface integrity.This research provides insights into the micromachining behavior of SiO2reinforced nanocomposites and serves as a foundation for further investigations into the machining of advanced composite materials.