Meso-scale numerical simulation and experimental verification of single grain grinding TiC–Fe composites

Abstract

Grinding process of particle reinforced metal matrix composites (PRMMCs) is extremely challenging due to the addition of hard particles. To reveal the material removal mechanism, a meso-scale numerical model for single grain grinding of TiC–Fe composites was established, considering the random particle distribution model and cohesive zone model. The simulated grinding forces and machined surface topography based on the proposed model show a similar trend and were consistent with the experimental results. The transition stage of ductile-brittle removal of TiC–Fe composites was explored. Results indicated that the grinding forces increase abruptly due to the obstruction of high-strength TiC particles and fluctuate periodically in the Fe matrix. The grinding forces decrease with the elevated grinding speed. Additionally, the material removal processes at different stages were studied and the removal modes mainly include: matrix plastic removal, particles wear, particles debonding, particles fracture, particles pull out. This paper provides significant guidance for the digitization and information construction of PRMMCs machining in enterprises and increases the economic benefits for the manufacturing industry.