Abstract
Mg2Si/Al composites have wide application prospects in aerospace and automotive industries. However, many defects often remain on the machined surface after micro cutting. In this paper, the formation mechanism of surface defects of Mg2Si/Al composites by micro cutting was studied by finite element (FE) simulations and machining experiments. Considering the real microstructure characteristics of Mg2Si particles, 2D FE simulations of Mg2Si/Al composites in micro cutting were carried out and then verified by corresponding cutting experiments. The simulation results and experimental data reveal the relationship between damage and deformation behavior of Mg2Si particles and formation mechanism of surface defects. In addition, the effects of cutting parameters such as depth of cutting (DoC), cutting speed and volume fraction of particles on residual defects of machined surfaces were studied. The results show that with lower DoC and higher cutting speed, the residual defects and surface roughness are significantly reduced, especially machining the composites with smaller particle size and lower volume fraction. The research findings provide a theoretical basis for reasonable selection of machining parameters and improving the machinability of Mg2Si/Al.
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