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Influence of the fiber orientation on 3D C/C–SiC composite material and its formation mechanism of the machining surface

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Abstract

Carbon/Carbon (C/C)–SiC composite materials attained much attention due to its unique properties like immense thermal conductivity, high corrosion, and abrasive resistance. Few scholars have systematically studied the grinding machinability of 3D C/C–SiC composite material. In this paper, the grinding experiment of 3D C/C–SiC composite material was carried out with a resin-bonded diamond grinding wheel. The effect of machining conditions on the grinding force, micromorphology, surface quality, and residual stress was studied, and the material removal mechanism was analyzed in-depth aimed at the three typical fiber orientations. The result shows that the surface roughness of different fiber areas follows the order: 90° fiber > 0° fiber > Normal fiber. The fiber’s orientation showed a significant effect on the mechanism of material removal. The residual thermal stress of C/C–SiC composite material increases from 32.25 to 207.43 MPa during the grinding process. Polishing the ground surface not only can remove the crack layer and residual stress layer but also can introduce residual compressive stress layer, which can effectively enhance the material strength. The 3D C/C–SiC composite material removal process is distinct from the composite material 2D C/C–SiC and the traditional brittle material. The main removal of C/C–SiC composite material is recognized as brittle fracture mode. Because of the different mechanical properties of carbon fiber, SiC matrix, and the pyrocarbon interface, the damage of material during grinding is asynchronous. The present work provides a comprehensive understanding for processing 3D C/C–SiC composite material parts with high quality.

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Data availability

Some or all data generated or used during the study are available from the corresponding author by request.

Code availability

Some or all code used during the study are available from the corresponding author by request.

Abbreviations

V s :

Grinding speed (m/s)

a p :

Grinding depth (μm)

Pyc:

Pyrocarbon

F t :

Tangential grinding force

F y :

Vertical force

D s :

Diameter of wheel (mm)

a gmax :

Maximum thickness of undeformed chip

C :

Grits density in the grinding area

∆b :

Maximum size among the subsurface and the ground surface

hkl:

Crystal plane index

ʋ:

Poisson’s ratio

ΔL :

Fracture size

f n :

Normal force

V w :

Feed speed (mm/min)

XRD:

X-ray diffraction

F n :

Normal grinding force

F h :

Horizontal force

θ :

Diamond grit top cone half-angle

Sa :

Arithmetical mean height

γ :

Half-angle of the cross-section of the undeformed chip

SEM:

Scanning electron microscope

σ φ :

Normal residual stress

E:

Elastic modulus

1/2S2 (hkl) :

X-ray elastic constant

f t :

Tangential force

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Acknowledgements

The presented work was funded by the National Natural Science Foundation of China (Grant Nos. 51875192, 52005174, 52075161), the Strategic Priority Research Program of the Chinese Academy of Sciences (Grant No. XD25020317), and the Natural Science Foundation of Hunan Province (Grant No. 2020JJ4193). The authors acknowledge the financial supports.

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Authors and Affiliations

  1. College of Mechanical and Vehicle Engineering, Hunan University, Changsha, 410082, Hunan, China

    Wei Li, Gui Long, Jia Yin & Jun Yang

  2. National Engineering Technology Research Center for High-Efficiency Grinding Technology, Hunan University, Changsha, 410082, Hunan, China

    Wei Li, Gui Long & Jia Yin

  3. College of Intelligent Science, National University of Defense Technology, Changsha, 410073, Hunan, China

    Feng Shi

  4. Shanghai Institute of Optics and Fine Mechanics, Chinese Academy of Sciences, Shanghai, 201800, China

    Shenlei Zhou

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  1. Wei Li
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  2. Gui Long
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  3. Feng Shi
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  4. Shenlei Zhou
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  5. Jia Yin
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  6. Jun Yang
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Contributions

WL contributed to the conception of the study; GL performed the experiment and was a major contributor in writing the manuscript; FS contributed significantly to analysis and manuscript preparation; SZ performed the experiment and wrote the manuscript; JYin and JYang helped perform the analysis with constructive discussions.

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Correspondence to Wei Li.

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Li, W., Long, G., Shi, F. et al. Influence of the fiber orientation on 3D C/C–SiC composite material and its formation mechanism of the machining surface. Int J Adv Manuf Technol 118, 2725–2743 (2022). https://doi.org/10.1007/s00170-021-08149-1

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