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Mechanistic force modeling in drilling of SiCp/Al matrix composites considering a comprehensive abrasive particle model

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Abstract

SiCp/Al composite is one of the key light metal matrix composites widely used in aerospace and electronics industries due to its excellent material properties. Understanding the mechanism of abrasive particle action and the cutting force generation is crucial for achieving desired hole quality and machining accuracy. However, there is no research on cutting force modeling in drilling of SiCp/Al composites. This paper proposes an energy-based mechanistic modeling method to predict the cutting force in drilling of SiCp/Al composites for the first time. A new comprehensive abrasive particle model considering different particle action mechanisms, such as cracking, debonding, and squeezing, is presented to depict the energy consumed by abrasive particle action. Experiments with a wide range of particle volume fractions and feed rates, and different particle sizes were carried out to validate the accuracy of the proposed model. Results show that the proposed model can accurately predict the cutting force with an average error of 6.55% in drilling of SiCp/Al composites. Furthermore, the energy consumed on abrasive particle action is estimated to be 8.2–13.6% of total cutting energy. The proposed model on SiCp/Al composites can be extended to other particle reinforced metal matrix composites.

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Abbreviations

A, B, C, m, n :

Parameters of J-C model

A i :

Contact area of particles embedded in the tool rake face (mm2)

b s :

Chip width (mm)

d, dc :

Depth of cut of the major and the chisel edge, respectively (mm)

E1, E2 :

Young’s modulus of the tool and the particle

E ∗ :

The composite elastic modulus

Em, Ec :

Energy consumed by the major cutting edge and the chisel edge, respectively (J/s)

\( {E}_{\mathrm{m}}^{\mathrm{s}},{E}_{\mathrm{c}}^{\mathrm{s}} \) :

Energy spends on shear zone of the major cutting edge and the chisel edge (J/s)

\( {E}_{\mathrm{m}}^{\mathrm{f}},{E}_{\mathrm{c}}^{\mathrm{f}} \) :

Energy spends on the tool-chip interface of the major cutting edge and the chisel edge (J/s)

\( {E}_{\mathrm{m}}^{\mathrm{p}},{E}_{\mathrm{c}}^{\mathrm{p}} \) :

Particle energy of the major cutting edge and the chisel edge (J/s)

\( {E}_{\mathrm{m}}^{\mathrm{n}},{E}_{\mathrm{c}}^{\mathrm{n}} \) :

Energy spends on new surface formation of the major cutting edge and the chisel edge (J/s)

\( {E}_{\mathrm{m}}^{\mathrm{pc}},{E}_{\mathrm{c}}^{\mathrm{pc}} \) :

Energy spends on the particle cracking of the major cutting edge and the chisel edge (J/s)

\( {E}_{\mathrm{m}}^{\mathrm{ps}},{E}_{\mathrm{c}}^{\mathrm{ps}} \) :

Energy spends on the particle squeezing of the major cutting edge and the chisel edge (J/s)

\( {E}_{\mathrm{m}}^{\mathrm{pd}},{E}_{\mathrm{c}}^{\mathrm{pd}} \) :

Energy spends on particle debonding of major cutting edge and secondary chisel edge (J/s)

f :

Feed rate (mm/r)

F a :

Force of extrusion zone (N)

Ff, Ffc :

Friction force of the major cutting edge and secondary chisel edge, respectively (N)

F N :

Sum of the normal force on individual abrasive particle (N)

F ni :

Normal force of individual abrasive particle (N)

Fpc, Fpd, Fps :

Force of particles cracking, debonding, and squeezing, respectively (N)

F tm :

Force of tool-matrix interface friction (N)

\( {F}_{\mathrm{tp}}^2 \) :

Force of the two-body abrasive friction (N)

\( {F}_{\mathrm{tp}}^3 \) :

Force of the three-body rolling friction (N)

Fs, Fsc :

Shear force of the major cutting edge and secondary chisel edge, respectively (N)

F Z :

Axial cutting force (N)

H tool :

Vickers hardness of the tool (MPa)

i :

Inclination angle (°)

i max :

Maximum of inclination angle (°)

k :

Drill point angle (°)

L :

Thickness of workpiece (mm)

L tc :

Length of tool-chip contact (mm)

N p :

Number of particles

Npc, Npd, Nps :

Number of the particles cracking, debonding, and squeezing

r g :

The radius of the groove (mm)

r i :

Radial distance (mm)

r x :

Transverse distance on the major cutting edge (mm)

R :

Radius of SiC particle (mm)

R a :

Radius of indentation zone (mm)

R c :

Fracture toughness of the material (kJ/m2)

R h :

Radius of the secondary chisel edge (mm)

s :

Spindle speed (rpm)

S pc :

Average cross-section area of an individual particle cracking (mm2)

Spd, Sps :

Average debonding and squeezing area of individual particle, respectively (mm2)

t :

Cutting time (s)

t 2 :

Volume fraction of the particles corresponding to the two-body abrasion (mm)

T :

Temperature raise in shear zone (K)

T 0 :

Room temperature (K)

T m :

Material melting temperature (K)

V c :

Cutting velocity (m/min)

Vf, Vfc :

Chip flow velocity of major cutting edge and secondary chisel edge, respectively (m/min)

V p :

Particle volume fraction (%)

Vs, Vsc :

Shear velocity of the major cutting edge and secondary chisel edge, respectively (m/min)

V Z :

Feed rate (mm/min)

w, wc :

Width of cutting of the major cutting edge and chisel edge, respectively (mm)

Xc, Xi, Xm :

The axial height of the extrusion zone, the secondary chisel edge and the major cutting edge, respectively (mm)

α, αc :

Rake angle of the major cutting edge and the secondary chisel edge, respectively (°)

α f :

Angle between the tangential and resultant velocity (°)

β :

Friction angle (°)

γ :

Shear strain

\( \dot{\gamma} \) :

Shear strain rate

δ p0 :

Groove depth of tool and particle (mm)

ζ :

Chip compression ratio

ϕ, ϕc :

Normal shear angle (°)

θ p :

Tool-particle angle of contact (°)

μ 3 :

Three-body rolling friction coefficient

υ1, υ2 :

Poission’ ratio of the major cutting edge and the chisel edge, respectively

σ b :

Cracking stress of the particle (MPa)

σ y :

Yield strength of the aluminum matrix (MPa)

σ p :

Particle debonding stress (MPa)

σ R :

Tensile strength of material (MPa)

τ :

Flow stress (MPa)

τ c :

Average shear stress of tool-chip contact (MPa)

ψ :

Chisel edge angle (°)

ω :

Half the thickness of the chisel edge (mm)

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Funding

This project is supported by National Natural Science Foundation of China (No. 51705362, No. 51905377), Natural Science Foundation of Tianjin (No. 18JCQNJC75600), Science and Technology Development Fund of Tianjin Education Commission for Higher Education (No. 2017KJ081, No. 2017KJ079), and the European Union’s Horizon 2020 research and innovation program (Grant No. 734272).

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Authors and Affiliations

  1. Tianjin Key Laboratory of Advanced Mechatronics Equipment Technology, Tiangong University, Tianjin, 300387, China

    Liu Chang, Xu Weiwei, Jiang Xiaogeng & Yang Tao

  2. School of Mechanical Engineering, Tiangong University, Tianjin, 300387, China

    Liu Chang, Xu Weiwei, Jiang Xiaogeng & Yang Tao

  3. School of Mechanical and Aerospace Engineering, Queen’s University Belfast, Belfast, BT9 5AH, UK

    Liu Chang & Jin Yan

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  1. Liu Chang
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  2. Xu Weiwei
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Chang, L., Weiwei, X., Yan, J. et al. Mechanistic force modeling in drilling of SiCp/Al matrix composites considering a comprehensive abrasive particle model. Int J Adv Manuf Technol 109, 421–442 (2020). https://doi.org/10.1007/s00170-020-05688-x

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