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The milling simulation and experimental research on high volume fraction of SiCp/Al

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Abstract

A multi-phase two-dimension finite element model has been developed by using ABAQUS/Explicit in order to describe the effect of reinforcement particles’ existence in SiCp/Al6063 composites on the machining process. It is used to simulate the high-speed milling process of high volume fraction SiCp/Al6063 composites. As comparison, the same machining process of matrix Al6063 is simulated with the HEM (homogenous equivalent material) model. These two models are verified with quasi-orthogonal slot milling tests. It is assumed that the variation of predicted milling forces with the feed rate is consistent with the experiments and the prediction error of the peak value of F y can be controlled within 10 %. Moreover, multi-phase model is helpful for discovering the miscellaneous interactions of matrix, particle and tool and the induced complicated stress distribution in the cutting area, for further obtaining an in-depth understanding of removal mechanism of SiCp/Al6063 composites.

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Authors and Affiliations

  1. Key Laboratory of Fundamental Science for Advanced Machining, Beijing Institute of Technology, Beijing, 100081, China

    Beibei Wang, Lijing Xie, Xiaolei Chen & Xibin Wang

Authors
  1. Beibei Wang
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  2. Lijing Xie
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  3. Xiaolei Chen
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  4. Xibin Wang
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Correspondence to Lijing Xie.

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Wang, B., Xie, L., Chen, X. et al. The milling simulation and experimental research on high volume fraction of SiCp/Al. Int J Adv Manuf Technol 82, 809–816 (2016). https://doi.org/10.1007/s00170-015-7399-1

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  • DOI: https://doi.org/10.1007/s00170-015-7399-1

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