Abstract
This paper presents an experimental study on precision milling of high volume fraction SiCP/Al composites with single flute polycrystalline diamond (PCD) end mills. Based on a series of tests, the present study is focused on surface roughness of machined surface and tool wear of single flute PCD end mills. The effect of cutting parameters such as feed per tooth (fz) and depth of cut (ap) on the machined surface roughness (Ra) was investigated. Tool wear was also inspected and analyzed by Scanning Electron Microscope (SEM). According to the results of experiment, there is a layer of aluminum covered on the machined surface. This layer of aluminum can improve the machined surface quality. Through the comparsion of surface roughness in different cutting parameters, it can decrease surface roughness (Ra) by means of using very small cutting parameters. Flank wear and chipping are two main kinds of tool wear. The observed wear mechanism of PCD tools is abrasive wear and adhesive wear. The purpose of this study is to provide an experimental result for further investigation on milling of high volume fraction SiCP/Al composites.
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