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Investigation on the removal characteristics of single-point cutting high-volume fraction SiCp/Al composites

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Abstract

SiC-reinforced aluminum matrix composites (SiCp/Al composites) are typically difficult-to-machine material, and the irregular SiC diffused in SiCp/Al composites make the surface quality worse. In this paper, a single-point cutting simulation with variable plane cutting depth were conducted for SiCp/Al composite with higher volume fraction (65 Vol%) and aluminum alloy. The surface morphology characteristics of SiCp/Al composites, which mainly include breaking, part breaking, pulling out, protruding, al tearing, and interface debonding, are different from those of aluminum alloy materials. The high-volume SiC lower the surface quality and profile dimensional accuracy of SiCp/Al composites. There are thin and discrete layers covered on the machined surface. Finally, a single-point cutting test, which meets the actual grinding condition, was conducted for 2A12 aluminum alloy, 45% SiCp/Al composite, and 65% SiCp/Al composite. The simulation results are verified by experimental data obtained from the single-point cutting test.

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Abbreviations

σ :

flow stress (Mpa)

A :

yield stress at reference temperature and strain rate (Mpa)

B :

strain hardening coefficient (Mpa)

ε :

plastic strain

n :

the strain hardening exponent

m :

thermal softening exponent

\( \overline{\varepsilon} \) :

strain rate

ε 0 :

reference plastic strain rate

T :

workpiece temperature(K)

T m :

material melting temperature(K)

T room :

room temperature(K)

d 1 -d 5 :

Failure parameters of matrix materials

w D :

scalar of failure state

Δε p :

equivalent plastic strain during each integration cycle

μ :

coefficient of sliding friction

ρ (e nn ck):

shear retention factor of material

p :

material parameters

ε f :

fracture strain

η :

stress triaxiality

p :

pressure stress (Mpa)

q :

von Mises equivalent stress (MPa)

ε p :

plastic strain rate

ε 0 :

reference strain rate

T r :

transition temperature defined as the one at or below which there is no temperature dependence on the expression of the fracture strain (K)

σ 1, σ 2, σ 3 :

principal stresses in three directions respectively (Mpa)

σ p :

tensile strength of material (Mpa)

τ :

friction force(N)

P:

positive pressure (Mpa)

σ b :

tensile strength of material

μ n0 :

normal displacement at failure

G f I :

mode I fracture energy

σ tu I :

failure stress

G s :

shear modulus after the crack opening

G :

shear modulus of the undamaged material

e nn ck :

cracking opening strain

e max ck :

material parameters

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The authors confirm that the data and material supporting the findings of this study are available within the article.

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Funding

This research was supported financially by the National Natural Science Foundation of China (NSFC) (Projects no. 51875079, U1908228) and Liaoning province “Xingliao Talents Program” young top talent (Projects no. XLYC1907196).

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Authors and Affiliations

  1. Marine Engineering College, Dalian Maritime University, Dalian, 116026, China

    Yong-jie Bao

  2. Engineering Training Center, Dalian University of Technology, Dalian, 116024, China

    Xu Zhang & Hong-zhe Zhang

  3. Department of Mechanical and Energy Engineering, Southern University of Science and Technology, Shenzhen, 518055, China

    Shou-xiang Lu

Authors
  1. Yong-jie Bao
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  2. Xu Zhang
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  4. Hong-zhe Zhang
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Contributions

Yong-jie Bao provides the support of research project. Yong-jie Bao, Shou-xiang Lu, and Hong-zhe Zhang developed the conceptual framework and research protocol for the study. Xu-Zhang completed the simulation analysis task. Shou-xiang Lu completed the task of single-point cutting test. Yong-jie Bao, Shou-xiang Lu, and Hong-zhe Zhang conducted the publication review and offered writing instructions. Xu Zhang drafted the manuscript and made major revisions. All authors approved the final version of the manuscript.

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Correspondence to Hong-zhe Zhang.

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We would like to submit our original research article entitled “Investigation on the removal characteristics of single-point cutting high-volume fraction SiCp/Al composites” to your journal named “The International Journal of Advanced Manufacturing Technology”. Neither the entire paper nor any part of its content has been published or has been accepted elsewhere. It is not being submitted to any other journal simultaneously.

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Bao, Yj., Zhang, X., Lu, Sx. et al. Investigation on the removal characteristics of single-point cutting high-volume fraction SiCp/Al composites. Int J Adv Manuf Technol 118, 881–894 (2022). https://doi.org/10.1007/s00170-021-07977-5

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  • DOI: https://doi.org/10.1007/s00170-021-07977-5

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