Abstract
The application of particulate reinforced metal matrix composite (PRMMC) has been increasing due to its superior strength and wear characteristics. The unique properties of PRMMC vary with respect to the volume fraction of reinforcement. In this paper a 2D Finite Element Analysis of A356/SiCp MMC during orthogonal turning is modelled and simulation is carried out using Abaqus as FE code. The main purpose of this study is to analyse the tool particle interactions and effect of volume fraction, size, shape and distribution during machining of A356/SiCp. In this model Lagrangian formulation approach is used. Johnson cook material model is employed for A356 and brittle cracking model is used for SiCp. Penalty contact method is used as the friction formulation with hard contact algorithm. The FE simulations are done for 0, 6, 12 and 15% of SiCp by volume, 60 and 12 micron of SiCp by size, circular & irregular shapes and uniform & irregular distribution of SiCp. The FE model created is validated with experimentally measured data, chip formation is simulated, tool-particle interaction is studied and effect of various volume fractions, sizes, shapes and distributions of SiCpin chip formation and stress pattern are analysed during the machining process using PCD tool insert.
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