Abstract
The aim of this work is to analyze the micro mechanisms underlying the wear of macroscale tools during diamond machining of SiCp/Al6063 composites and to develop the mechanism-based diamond wear model in relation to the dominant wear behaviors. During drilling, high volume fraction SiCp/Al6063 composites containing Cu, the dominant wear mechanisms of diamond tool involve thermodynamically activated physicochemical wear due to diamond-graphite transformation catalyzed by Cu in air atmosphere and mechanically driven abrasive wear due to high-frequency scrape of hard SiC reinforcement on tool surface. An analytical diamond wear model, coupling Usui abrasive wear model and Arrhenius extended graphitization wear model was proposed and implemented through a user-defined subroutine for tool wear estimates. Tool wear estimate in diamond drilling of SiCp/Al6063 composites was achieved by incorporating the combined abrasive-chemical tool wear subroutine into the coupled thermomechanical FE model of 3D drilling. The developed drilling FE model for reproducing diamond tool wear was validated for feasibility and reliability by comparing numerically simulated tool wear morphology and experimentally observed results after drilling a hole using brazed polycrystalline diamond (PCD) and chemical vapor deposition (CVD) diamond coated tools. A fairly good agreement of experimental and simulated results in cutting forces, chip and tool wear morphologies demonstrates that the developed 3D drilling FE model, combined with a subroutine for diamond tool wear estimate can provide a more accurate analysis not only in cutting forces and chip shape but also in tool wear behavior during drilling SiCp/Al6063 composites. Once validated and calibrated, the developed diamond tool wear model in conjunction with other machining FE models can be easily extended to the investigation of tool wear evolution with various diamond tool geometries and other machining processes in cutting different workpiece materials.
Highlights
Silicon carbide particulate reinforced aluminum matrix (SiCp /Al) composites have been of great potential due to their superior physical and mechanical properties, such as high stiffness-to-weight ratio, high specific strength, high wear resistance, low sensitivity to temperature variations and excellent corrosion resistance [1]
The modeling of drill bit is is only focused on the tool tip part involving realistic drilling and the sharp edges is considered owing only focused on the tool tip part involving realistic drilling and the sharp edges is considered owing to newly-received drill bit employed at the beginning of drilling (Figure 5a)
The motions for tool to newly-received drill bit employed at the beginning of drilling
Summary
Silicon carbide particulate reinforced aluminum matrix (SiCp /Al) composites have been of great potential due to their superior physical and mechanical properties, such as high stiffness-to-weight ratio, high specific strength, high wear resistance, low sensitivity to temperature variations and excellent corrosion resistance [1]. This composite material has a promising application prospect in many advanced industries such as aerospace, marine, automotive and sport equipment [2,3]. The diamond, diamond coated and diamond-like tools are considered one of the most favorable ones for cutting these materials [10,11]
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