Investigation on the removal characteristics of single-point cutting high-volume fraction SiCp/Al composites

Yong-Jie Bao,Hong-Zhe Zhang,Xu Zhang,Shou-Xiang Lu

doi:10.1007/s00170-021-07977-5

Abstract

SiC-reinforced aluminum matrix composites (SiCp/Al composites) are typically difficult-to-machine material, and the irregular SiC diffused in SiCp/Al composites make the surface quality worse. In this paper, a single-point cutting simulation with variable plane cutting depth were conducted for SiCp/Al composite with higher volume fraction (65 Vol%) and aluminum alloy. The surface morphology characteristics of SiCp/Al composites, which mainly include breaking, part breaking, pulling out, protruding, al tearing, and interface debonding, are different from those of aluminum alloy materials. The high-volume SiC lower the surface quality and profile dimensional accuracy of SiCp/Al composites. There are thin and discrete layers covered on the machined surface. Finally, a single-point cutting test, which meets the actual grinding condition, was conducted for 2A12 aluminum alloy, 45% SiCp/Al composite, and 65% SiCp/Al composite. The simulation results are verified by experimental data obtained from the single-point cutting test.

Highlights

SiCp/Al composites with high SiC particles volume fraction have excellent physical and mechanical properties, including high specific strength, high specific modulus, good wear resistance, high temperature resistance, low thermal expansion coefficient and good dimensional stability [1,2,3]
The results indicated that the particle size has significant influence on the surface quality of the machine surface of SiCp/Al mechanism of SiC particle-reinforced aluminum matrix composites (MMCs) and the fracture and removal of particle shows significant effect on the surface generation
Material accumulation appeared on both sides of scratch centerline showing plastic flow features

Summary

Introduction

SiCp/Al composites with high SiC particles volume fraction have excellent physical and mechanical properties, including high specific strength, high specific modulus, good wear resistance, high temperature resistance, low thermal expansion coefficient and good dimensional stability [1,2,3]. Liu et al [13] and Wu et al [14] using the finite element models studied the material removal mechanism and defect formation mechanism of SiCp/Al composites considering tool and SiC particles interaction in different positions. The main difference between the model of 2a12 aluminum alloy and SiCp/Al composites is whether the workpiece contains sic particles or not.

Results

Conclusion