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Research on chip formation mechanism and surface morphology of particle-reinforced metal matrix composites

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Abstract

In this paper, a finite element (FE) cutting model for particle-reinforced metal matrix composites (PRMMCs) considering material damage was developed to predict SiC particle failure, cutting forces, and machined surface topography in SiCp/Al composite machining, and to analyze the dynamic mechanisms of chip formation and particle failure evolution. The validity of the simulation model was verified by comparing the simulation results with the cutting forces and surface topography obtained from the milling machining experiments. It was found that complex stress-strain fields exist in SiCp/Al composites with mesoscopic non-homogeneous structures, and alternating reticulation of tensile and compressive stress between particles was observed; particle failure due to tool-workpiece interaction exists in both direct and indirect ways; particle failure and local chip deformation during machining affect surface topography and chip shaping, resulting in serrated chips, pitting on the machined surface, and residual particle fragments.

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Acknowledgements

The authors appreciate the support from the National Natural Science Foundation of China (Grant No. 51575289 and Grant No.51705270).

Funding

This study is supported by the National Natural Science Foundation of China (Grant No. 51575289 and Grant No. 51705270).

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Authors and Affiliations

  1. School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao, 266525, China

    Yuxin Fang, Youqiang Wang & Heng Luo

  2. Key Lab of Industrial Fluid Energy Conservation and Pollution Control, Ministry of Education, Qingdao, 266520, China

    Yuxin Fang, Youqiang Wang & Heng Luo

  3. School of Mechanical and Power of Engineering, East China University of Science and Technology, Shanghai, 200237, China

    Ping Zhang

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  1. Yuxin Fang
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  4. Heng Luo
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Contributions

This paper further explores the dynamic mechanisms of chip formation and particle failure in the machining of SiCp/Al composites to provide some theoretical references for the optimization of composite design and cutting technology.

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Correspondence to Youqiang Wang or Ping Zhang.

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Fang, Y., Wang, Y., Zhang, P. et al. Research on chip formation mechanism and surface morphology of particle-reinforced metal matrix composites. Int J Adv Manuf Technol 117, 3793–3804 (2021). https://doi.org/10.1007/s00170-021-07921-7

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