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Finite element modeling on micro-machining of graphene-reinforced aluminum matrix composites

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Abstract

Graphene-reinforced metal matrix composites have received a lot of attention from academia and industry due to their excellent mechanical properties. In this paper, the machinability of graphene-reinforced aluminum metal matrix composites (Gr/Al MMCs) during micro-machining is investigated by finite element method. A three-dimensional modeling program based on the Python language is developed independently; this program can generate graphene with random distribution of orientation and position. A three-dimensional two-phase finite element model considering the cutting edge radius is established to simulate the micro-machining process of Gr/Al MMCs. Embedded element method is used in the model to more efficiently simulate the interaction behavior between graphene and aluminum matrix during micro-machining. The accuracy of the model is verified by indirect experiments. Stress distribution, tool-graphene interaction, chip formation, cutting force, and specific cutting energy during micro-machining are investigated with different uncut chip thickness. The simulation results show that graphene inhibits stress propagation, resulting in the formation of a stress field with irregular contours within the matrix. Continuous serrated chips are generated during the cutting process. The addition of graphene increases the magnitude and fluctuation of cutting forces.

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The data and data sources relevant to this study are disclosed in the manuscript.

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Funding

The research presented in this document was supported by the Scientific Research Project of Tianjin Municipal Education Commission (2020KJ015), the Research Fund for the Natural Science Project of Tianjin Education Commission (2018KJ240), and the Tianjin excellent special agent project (20YDTPJC01720).

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Authors and Affiliations

  1. College of Aeronautical Engineering, Civil Aviation University of China, Tianjin, 300300, China

    Hao Yu, Zhenpeng He, Baichun Li, Jia Xin & Lianzheng Yao

  2. School of Mechanical Engineering, Shenyang University of Technology, Shenyang, 110870, China

    Jinbo Li

  3. Tianjin Bu Er Technology Co, Ltd, Tianjin, 300300, China

    Fangchao Yan

Authors
  1. Hao Yu
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  2. Zhenpeng He
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  3. Jinbo Li
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  4. Baichun Li
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  5. Jia Xin
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  6. Lianzheng Yao
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  7. Fangchao Yan
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Contributions

Zhenpeng He and Baichun Li contributed to the conception and design of this study. Hao Yu, Zhenpeng He, and Jinbo Li were involved in the finite element modeling and simulation results analysis. Baichun Li and Fangchao Yan developed a Python-based modeling program. Jia Xin and Lianzheng Yao was involved in the data collection and made constructive suggestions. The first draft of the manuscript was written by Hao Yu, and all the authors commented on previous versions of the manuscript. All the authors read and approved the final manuscript.

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Correspondence to Baichun Li.

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Yu, H., He, Z., Li, J. et al. Finite element modeling on micro-machining of graphene-reinforced aluminum matrix composites. Int J Adv Manuf Technol 124, 97–110 (2023). https://doi.org/10.1007/s00170-022-10476-w

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  • DOI: https://doi.org/10.1007/s00170-022-10476-w

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