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Study on the milling surface quality of 20% volume fraction SiCp/Al composites

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Abstract

During milling, brittle fracture occurs in SiCp/Al composites due to extrusion, while plastic deformation occurs in the aluminum matrix. The damage of particles and the matrix is different. In order to observe the brittle fracture process of particles more accurately, a single particle milling model was established to analyze the damage and deformation of particles when cutting along different positions. In the study of the influence of cutting speed on particle failure, a two-dimensional simulation model with multi-particle random distribution was established. Keeping the cutting depth the same, only the cutting speed was varied to study its effect on the surface quality. Detailed analysis of the orthogonal test results shows that the influence on surface quality is from feed rate, milling speed, and milling depth in descending order. The optimal cutting conditions are milling speed of 47.10 m/min, feed speed of 10 mm/min, and cutting depth of 80 μm. Through the analysis of sub-surface morphology, the main causes of cracks, pits, and other defects on machined surfaces can be explained, and the experimental results are proved to be the same as the simulation results.

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Availability of data and material

The data used to support the findings of this study are available from the corresponding author upon request.

Abbreviations

σ:

Flow stress

\(\varepsilon\) :

Strain

A:

Initial yield stress

B:

Material strain hardening modulus

C:

Strain rate strengthening index

n:

Material hardening index

\(\dot{\varepsilon }\) :

Effective plastic strain rate

\(\dot{{\varepsilon }_{0}}\) :

Reference plastic strain rate

T:

Deformation temperature

\({T}_{r}\) :

Reference temperature

\({T}_{m}\) :

Melting temperature

m:

Temperature sensitivity constant

\({\upvarepsilon }_{\mathrm{f}}\) :

Failure strain

\(\mathrm{\Delta \varepsilon }\) :

Effective plastic strain increment in the state of increasing load units.

\({\varepsilon }_{f}\) :

Plastic strain of the material

\({D}_{1}\) to \({D}_{5}\) :

Material failure model coefficients

\(p\) :

Main principal stress

\(q\) :

Flow stress

\({\upsigma }_{1},{\upsigma }_{2},{\upsigma }_{3}\)  :

Principal stress components

\({\sigma }_{0}\) :

Tensile stress of the material

\({\mathrm{G}}_{\mathrm{f}}^{1}\) :

Type I fracture energy

\({\upsigma }_{\mathrm{tu}}^{\mathrm{I}}\) :

Failure stress at the time of crack formation

G:

Shear modulus of material failure

\({\mathrm{e}}_{\mathrm{nn}}^{\mathrm{ck}}\) :

Crack extension strain

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Funding

This work was supported by the National Natural Science Foundation of China (No. 51905083) and the Doctoral Start-up and Youth Project Fund of Liaoning Province (2019-BS-123).

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Authors and Affiliations

  1. School of Mechanical Engineering and Automation, Liaoning University of Technology, Jinzhou, 121001, China

    Ke Zhang, Qi Gao, Ye Chen, Tianyang Cui & Xunyu Yin

  2. Institute of Metal Research, Chinese Academy of Science, Shenyang, 110016, China

    Quanzhao Wang

Authors
  1. Ke Zhang
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  2. Qi Gao
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  4. Ye Chen
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Contributions

Zhang did all the milling experiments and wrote the papers. Gao guided Zhang to revise the paper. Wang made a parameter measurement of the material used in this experiment. Chen, Cui, and Yin helped with the experimental process. All authors read and approved the manuscript.

Corresponding author

Correspondence to Qi Gao.

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Zhang, K., Gao, Q., Wang, Q. et al. Study on the milling surface quality of 20% volume fraction SiCp/Al composites. Int J Adv Manuf Technol 122, 1555–1566 (2022). https://doi.org/10.1007/s00170-022-09949-9

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  • DOI: https://doi.org/10.1007/s00170-022-09949-9

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