Influence of particle parameters on micro-machining performance of CoCrFeNiAlX/Al composite materials

Abstract

This study delves into the influence of particle size on the micro-machining performance of CoCrFeNiAlXp/Al composite materials. It employs a combination of experimental and simulation methods to investigate the effect of different particle sizes on the surface integrity of the composite material. The research also scrutinizes the impact of tool particle size on cutting forces, cutting temperatures, and chip morphology across a range of cutting parameters. Additionally, it establishes a clear link between the quality of the machined surface and the relative position of the tool particles. The findings reveal that an increase in particle diameter leads to a reduction in cutting forces. Furthermore, at a constant particle size, an initial rise in cutting speed results in an increased cutting force, which subsequently decreases. Specifically, the maximum cutting force is observed at a particle size of 10 μm, reaching its peak at a cutting speed of 60 m/min, approximately 1.6 times that of the 40 μm particle size. The primary cutting force displays a positive correlation with cutting depth but a negative correlation with particle diameter. For particles of uniform size, an increment in the Al element content initially reduces the cutting force, which subsequently increases, with the minimum force occurring at an Al element molar ratio of 13 %, roughly 60 % of the Al0 particle. Cutting temperature rises with higher cutting speed and depth but inversely correlates with particle diameter and Al content. A particle size of 10 μm generates the highest cutting temperature, approximately 1.4 times that of a 40 μm particle with identical Al content. The completeness of the chip positively correlates with cutting speed, but at a speed of 70 m/min, chip breakage experiences a significant upsurge. The bending radius of the chip increases with cutting depth, ultimately leading to fracture at a depth of 60 μm. A higher Al content in the particles results in more pronounced chip breakage. The optimal surface quality is achieved when the tool is positioned above the particles, while positioning it below or at a 1/2 distance from the particles is more likely to cause damage to the machined surface.