Cutting Force Prediction Model for Elliptical Vibration Cutting SiCp/Al Based on Three-Phase Friction Theory

Yucheng Liu ,Cui Wang,Xu Zhang

doi:10.3390/app112210737

Abstract

The friction behavior in the tool-chip interface is an essential issue in aluminum matrix composite material (AMCM) turning operations. Compared with conventional cutting, the elliptical vibration (EVC) cutting AMCM has attractive advantages, such as low friction, small cutting forces, etc. However, the friction mechanism of the EVC cutting AMCM is still inadequate, especially the model for cutting forces analyzing and predicting, which hinders the application of EVC in the processing of AMCM. In this paper, a cutting force prediction model for EVC cutting SiCp/Al is established, which is based on the three-phase friction (TPF) theory. The friction components are evaluated and predicted at the tool-chip interface (TCI), tool-particle interface (TPI) and tool-matrix (TMI), respectively. In addition, the tool-chip contact length and SiC particle volume fraction were defined strictly and the coefficient of friction was predicted. Based on the Johnson-Cook constitutive model, the experiment was conducted on SiCp/Al. The cutting speed and tool-chip contact length were used as input parameters of the friction model, and the dynamic changes of cutting force and stress distribution were analyzed. The results shown that when cutting speed reaches 574 m/min, the tool-chip contact length decreases to 0.378 mm. When the cutting speed exceeds 658 m/min, the cutting force decreases to a minimum of 214.9 N and remains stable. In addition, compared with conventional cutting, the proposed prediction model can effectively reduce the cutting force.

Highlights

Aluminum-based composite material is a high-quality composite material composed of an aluminum metal matrix and a certain volume fraction of silicon carbide particles [1]
This paper proposes a new friction force prediction model based on three-phase friction theory and elliptical vibration cutting (EVC) intermittent cutting, which takes into account compound friction and single friction behavior that traditional models ignore
It is an important cause of built-up edge; (b) tool-particle interface (TPI): as the volume fraction of the SiC reinforcement in the bottom layer of the chip continues to increase, the binding force of the aluminum matrix to the SiC reinforcement continues to decline until the constraint force is not sufficient to resist friction, and the SiC particles fall off the Tool-chip interface to a critical value

Summary

Introduction

Aluminum-based composite material is a high-quality composite material composed of an aluminum metal matrix and a certain volume fraction of silicon carbide particles [1]. Due to the large pressure between the bottom layer of the chip, the rake face of the tool and high-temperature adhesion friction, a small amount of material is adhered to the tool It is an important cause of built-up edge; (b) TPI: as the volume fraction of the SiC reinforcement in the bottom layer of the chip continues to increase, the binding force of the aluminum matrix to the SiC reinforcement continues to decline until the constraint force is not sufficient to resist friction, and the SiC particles fall off the Tool-chip interface to a critical value. The above analysis gives us reason to believe that the normal force in EVC can be obtained from the double integral equation of two variables in normal force: σmax (t2 − t1)

Friction Force Prediction at TCI Based on TPF

Results and Discussion

Conclusions