Abstract
The machining process of SiC/Al matrix composites is characterized by strong nonlinearity, and thus, there are great challenges resulting from excessive deformation and stress concentration at the tool-workpiece interface in solving such problems. Smoothed particle hydrodynamics (SPH) as a particle-based algorithm can efficiently tackle mesh distortion due to large deformation using finite element method (FEM) for cutting simulations. However, the computational efficiency by SPH is far below the counterpart by FEM. As a result, to address such issues with individual use of SPH or FEM, the coupled SPH-FEM algorithm is presented to calculate large deformation of aluminum matrix using SPH and small deformation of SiC particles using FEM. This paper aims to develop a SPH-FEM coupling model of machining SiC/Al matrix composites and compare the results with an equivalent FE model. A good agreement between numerical results from the SPH-FEM model and those from the FE model is achieved, which shows that the SPH-FEM coupling method is an alternative to FEM for predicting the cutting force, chip formation, and machined surface morphology. The developed SPH-FEM model is also employed to investigate the influence of the cutting parameters including SiC volume fraction, cutting velocity, and uncut chip thickness on the cutting force. Finally, the orthogonal cutting experiments were conducted to validate the presented SPH-FEM model. Numerical results are in good agreement with experimental results, which confirms that SPH-FEM can accurately predict the resulting cutting force and machined surface morphology.
Similar content being viewed by others
Availability of data and materials
The data and materials that support the findings of this study are available from the corresponding author upon reasonable request.
References
Liao Z, Abdelhafeez A, Li H, Yang Y, Axinte D (2019) State-of-the-art of surface integrity in machining of metal matrix composites. Int J Mach Tool Manu 143:63–91
Xiang J, Xie L, Gao F, Yi J, Pang S, Wang X (2017) Diamond tools wear in drilling of SiCp/Al matrix composites containing copper. Ceram Int 44:5341–5351
Duan C, Sun W, Fu C, Zhang F (2018) Modeling and simulation of tool-chip interface friction in cutting Al/SiCp composites based on a three-phase friction model. Int J Mech Sci 142–143:384–396
Yin W, Duan C, Li Y, Miao K (2021) Modelling of tool flank-workpiece interface friction considering temperature gradient and particle property for cutting SiCp/Al composites. J Mater Process Tech 298:117302
Umer U, Kishawy H, Ghandehariun A, Xie L, Ahmari AA (2017) On modeling tool performance while machining aluminum-based metal matrix composites. Int J Adv Manuf Tech 104:1–12
Teng X, Chen W, Huo D, Shyha I, Lin C (2018) Comparison of cutting mechanism when machining micro and nano-particles reinforced SiC/Al metal matrix composites. Compos Struct 203:636–647
Wang Y, Liao W, Yang K, Chen W, Liu T (2018) Investigation on cutting mechanism of SiCp/Al composites in precision turning. Int J Adv Manuf Tech 100:963–972
Wu Q, Xu W, Zhang L (2019) Machining of particulate-reinforced metal matrix composites: an investigation into the chip formation and subsurface damage. J Mater Process Tech 274:116315
Ducobu F, Riviere-Lorphevre E, Filippi E (2016) Application of the coupled Eulerian-Lagrangian (CEL) method to the modeling of orthogonal cutting. Eur J Mech A / Solids 59:58–66
Ducobu F, Riviere-Lorphevre E, Filippi E (2017) Finite element modelling of 3D orthogonal cutting experimental tests with the coupled Eulerian-Lagrangian (CEL) formulation. Finite Elem Anal Des 134:27–40
Ng EG, El-Wardany TI, Dumitrescu M, Elbestawi MA (2002) Physics-based simulation of high speed machining. Mach Sci Technol 6:301–329
Ye T, Pan DY, Huang C, Liu M (2019) Smoothed particle hydrodynamics (SPH) for complex fluid flows: recent developments in methodology and applications. Phys Fluids 31:11301
Lind SJ, Rogers BD, Stansby PK (2020) Review of smoothed particle hydrodynamics: towards converged Lagrangian flow modelling. P Roy Soc A Math Phy 2241:20190801
Islam M, Chong P (2019) A total Lagrangian SPH method for modelling damage and failure in solids. Int J Mech Sci 5:157–158
Koneshwaran S, Thambiratnam DP, Gallage C (2015) Blast response of segmented bored tunnel using coupled SPH-FE method. Structures 2:58–71
Magliaro J, Altenhof W (2020) Mechanical performance and crashworthiness of plates and extrusions subjected to cutting: an overview. Thin Wall Struct 148:106612
Dou W, Geng X, Xu Z (2019) Experimental investigation and numerical simulation of the orthogonal cutting based on the smoothed particle hydrodynamics method. J Manuf Process 44:359–366
Wang J, Zhang A, Fang F (2020) Numerical study via total Lagrangian smoothed particle hydrodynamics on chip formation in micro cutting. Adv Manuf 8:144–159
Niu W, Mo R, Liu G, Sun H, Wang G (2018) Modeling of orthogonal cutting process of A2024–T351 with an improved SPH method. Int J Adv Manuf Tech 95:905–919
Guo X, Li M, Dong Z, Zhai R, Kang R (2019) Smooth particle hydrodynamics modeling of cutting force in milling process of TC4. Adv Manuf 7:364–373
Takabi B, Tajdari M, Tai BL (2017) Numerical study of smoothed particle hydrodynamics method in orthogonal cutting simulations-effects of damage criteria and particle density. J Manuf Process 30:523–531
Zhang S, Zhang H, Zong W (2019) Modeling and simulation on the effect of tool rake angle in diamond turning of KDP crystal. J Mater Process Technol 273:116259
Zhang S, Zong W (2021) FE-SPH hybrid method to simulate the effect of tool inclination angle in oblique diamond cutting of KDP crystal. IJMS 196:1–13
Song H, Pan P, Ren G, Yang Z, Xu J (2020) SPH/FEM modeling for laser-assisted machining of fused silica. Int J Adv Manuf Tech 106:2049–2064
Swiftr P (2001) SPH elastic dynamics. Comput Methods Appl Mech Eng 190:6641–6662
Hu W, Rakhsha, Yang L, Kamrin K, Negrut D (2021) Modeling granular material dynamics and its two-way coupling with moving solid bodies using a continuum representation and the SPH method. Comput Methods Appl Mech Engrg 385:114022
Islam MRI, Peng C (2019) A total Lagrangian SPH method for modelling damage and failure in solids. Int J Mech Sci 5:157–158
Monaghan JJ, Gingold RA (1983) Shock simulation by the particle method SPH. J Comput Phys 52:374–389
Kim NH, Owen DRJ (2015) Introduction to nonlinear finite element analysis. Springer, Department of Mechanical and Aerospace Engineering, University of Florida, Gainesville, FL, USA
Liu J, Bai Y, Xu C (2014) Evaluation of ductile fracture models in finite element simulation of metal cutting processes. J Manuf Sci E 136:011010
Zhang J, Ouyang Q, Guo Q, Li Z, Fan G, Yu Y, Jiang L, Enrique JL, Julie MS, Zhang D (2016) 3D Microstructure-based finite element modeling of deformation and fracture of SiCp/Al composites. Compos Sci Technol 123:1–9
Wu Q, Xu W, Zhang L (2019) Microstructure-based modelling of fracture of particulate reinforced metal matrix composites. Compos Part B Eng 163:384–392
Kannan S, Kishawy HA, Deiab I (2009) Cutting forces and TEM analysis of the generated surface during machining metal matrix composites. J Mater Process Tech 209:2260–2269
Funding
This study was supported by the National Natural Science Foundation of China (Grant No. 51675144), and the Natural Science Foundation of Heilongjiang Province (Grant No. LH2020E064).
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Ethics approval
Complied with ethical standards.
Consent to participate and consent for publication
All authors agree to contribute and publish the article.
Competing interests
The authors declare no competing interests.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Teng, X., Xiao, D. & Jiang, X. Numerical investigation of machining of SiC/Al matrix composites by a coupled SPH and FEM. Int J Adv Manuf Technol 122, 2003–2018 (2022). https://doi.org/10.1007/s00170-022-09985-5
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-022-09985-5