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Study on micro-grinding mechanism and surface quality of high-volume fraction SiCp/Al composites

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Abstract

SiCp/Al composites contain fine reinforcing particles with high hardness and rigidity, which makes the processing more difficult. The surface roughness prediction model was established and the micro-grinding mechanism was revealed. A non-homogeneous finite element simulation model for the high-volume fraction SiCp/Al composites grinding process was established. Based on the response surface method (RSM), an electroplated diamond grinding rod with a diameter of 1 mm was used to conduct micro-grinding experiments on SiCp/Al composite materials whose SiC particles accounted for 60 %. The results show that the spindle speed has the most significant influence on the surface roughness, followed by grinding depth and feed rate. The minimum surface roughness of micro-grinding is 0.51 μm. Based on the analysis of micro-grinding simulation model and the surface morphology detected by scanning electron microscopy, the grinding mechanism of high-volume fraction SiCp/Al composites were put forward which mainly embodied in brittle fracture and pull-out of particles.

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Abbreviations

Ra :

Surface roughness

n :

Spindle speed

f :

Feed rate

a p :

Grinding depth

σ :

Misses flow stress

A :

Initial yield stress

B :

Strain hardening parameter of the material

C :

Strengthening parameter of material strain rate

N :

Hardening index

M :

Thermal softening index of the material

T melt :

Temperature of the material’s melting point

T 0 :

Room temperature

F :

The significance of the model

R 2 :

The coefficient of determination

R 1 2 :

The adjustable coefficient

D 1-D 5 :

The coefficient of failure

x i :

Independent variable factor

γ :

Dependent variable factor

β 0 :

Constant term

β i :

Correlation coefficient of the first order term

β ij :

Nonlinear correlation parameter

β ii :

Quadratic correlation coefficient

m :

The number of independent variables

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Acknowledgments

This work is supported by: 1. the National Natural Science Foundation of China (No. 51775100); 2. the Doctoral Start-up Fund of Liaoning Province (2019-BS-123).

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Authors and Affiliations

  1. College of Mechanical Engineering and Automation, Liaoning University of Technology, Jin Zhou, 121001, China

    Qi Gao & Guangyan Guo

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

    Quanzhao Wang

Authors
  1. Qi Gao
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  2. Guangyan Guo
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  3. Quanzhao Wang
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Corresponding author

Correspondence to Qi Gao.

Additional information

Qi Gao is an Associate Professor at Liaoning University of Technology. He received a Doctorate in Mechanical Engineering from Northeastern University. His research interests include micro precision process, digital manufacturing.

Guangyan Guo is a graduate student at Liaoning University of Technology. He received a Bachelor’s degree in Mechanical Engineering from the Qingdao University of Science and Technology. His research interests are micro-scale grinding and milling.

Quanzhao Wang works in the Institute of Science. He received a Doctorate in the Institute of Metal Research, Chinese Academy of Science. His research interests include materials processing engineering and digital manufacturing.

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Gao, Q., Guo, G. & Wang, Q. Study on micro-grinding mechanism and surface quality of high-volume fraction SiCp/Al composites. J Mech Sci Technol 35, 2885–2894 (2021). https://doi.org/10.1007/s12206-021-0612-2

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  • DOI: https://doi.org/10.1007/s12206-021-0612-2

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