Abstract
Carbon fiber-reinforced silicon carbide matrix composites (Cf/SiCs) are a new thermos-structural material widely used in aviation and aerospace. The brazed diamond grinding rod is used to machine different surfaces of 3D-Cf/SiCs to investigate the influence of fiber orientations on the grinding process. A unidirectional Cf/SiCs model is built for grinding simulation. The influence of parameters on the grinding force and temperature is investigated. The morphology and roughness Sa of a machined surface are observed. In addition, the material removal mechanisms of Cf/SiCs and the wear mechanisms of the grinding rod are studied. The results reveal that the process parameters, including grinding rate vc, feed rate f, and grinding depth, significantly influence the grinding force and temperature. The grinding force and temperature are approximately the same when grinding on surfaces A, B, and C of Cf/SiCs. Moreover, according to the simulation results, the grinding force is maximal when grinding along the fiber end face. Tearing, delamination, and cavities are the main defects. The morphologies and Sa of warp, weft, and Z-directional yarns are inconsistent when grinding on surfaces A, B, and C of Cf/SiCs. In addition, the Sa is the lowest when grinding along the fiber end face. As the grinding depth increases, compression and shear-induced fracture inside carbon fibers change to bending-induced fracture over the entire fiber. There are two mechanisms for the formation of carbon fiber chips, fracture due to internal crack expansion or fracture due to bending stress after debonding. The surface quality of the carbon fiber fracture is worst when grinding along the fiber end face. The main wear mechanisms of the brazed diamond grinding rod are abrasive wear and PCD grain rupture. As the abrasive grains are worn, the grinding force and grinding temperature increase, and Sa decreases and then increases.
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