Research on chip formation mechanism and surface morphology of particle-reinforced metal matrix composites

Yuxin Fang,Heng Luo,Youqiang Wang,Ping Zhang

doi:10.1007/s00170-021-07921-7

Abstract

In this paper, a finite element (FE) cutting model for particle-reinforced metal matrix composites (PRMMCs) considering material damage was developed to predict SiC particle failure, cutting forces, and machined surface topography in SiCp/Al composite machining, and to analyze the dynamic mechanisms of chip formation and particle failure evolution. The validity of the simulation model was verified by comparing the simulation results with the cutting forces and surface topography obtained from the milling machining experiments. It was found that complex stress-strain fields exist in SiCp/Al composites with mesoscopic non-homogeneous structures, and alternating reticulation of tensile and compressive stress between particles was observed; particle failure due to tool-workpiece interaction exists in both direct and indirect ways; particle failure and local chip deformation during machining affect surface topography and chip shaping, resulting in serrated chips, pitting on the machined surface, and residual particle fragments.

Highlights

Particle reinforced metal matrix composites machining of PRMMCs[8,9]
While the addition of particle reinforcement greatly particles with less sharp angles are closer to spherical improves the overall properties of composites, shape, which provides meaningful reference for using it brings about undesirable problems circular SiC particles in found that the (FE) modeling, as are already such as severe tool wear and poor surface machining widely used in the simulation of PRMMCs
The material deformation becomes more severe, and continuously broken particles cause small cracks and holes to appear within the composite material (Fig.4(d)), and extreme shear deformation in the primary shear zone during chip formation causes a large number of particles to fracture (Fig.4(e))

Summary

Introduction

Particle reinforced metal matrix composites machining of PRMMCs[8,9]. The mechanical (PRMMCs), as represented by SiCp/Al composite, are widely application in automobile, aerospace, and property of SiCp/Al composites is affected by the size and volume fraction of the Silicon carbide(SiC). The addition of the SiC particle reinforcement process of chips during machining process directly by phase leads to complex tool-particle interactions experiment[4,5] To solve this problem, finite element during machining, and further studies found that the (FE) technique has been widely applied[6,7]. Tool Rake face SiC Particle the single closure theory is not suitable for studying the complex-structured PRMMCs, so finite element computational micromechanics (FECM) has been widely used to simulate their chip separation process[27,28,29,30] With this strategy, one can to derive the overall response of the composite material, and work out the details of stress and strain fields and tool-workpiece interactions in the mesostructure of the multiphase material, and to further understand the chip formation mechanism of the composite. The size of the workpiece is 0.5×0.2 mm, the SiC particles were simplified to be round and uniformly randomly distributed, with average particle size of 5

Material constitutive model

Chip separation criteria

Meshing and boundary conditions

Chip formation process

Conclusion ajority of fractured particles in the cutting path a