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Study on micro-grinding mechanism and surface and subsurface quality of 20 vol% SiCp/Al composites

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Abstract

A finite element model of single abrasive grinding was established to analyze the material removal during the grinding process and analyze the surface and subsurface defects of the material after grinding. Using the orthogonal test method to machine the surface of the workpiece with a grinding rod of 2 mm grinding head diameter, and to investigate the influence degree of the machining parameters on the roughness. It was concluded that the grinding depth has the most significant effect on surface roughness, followed by the spindle speed and the feed speed, and the minimum roughness of the ground surface obtained was 0.066 µm. The rough surface was simulated by the digital filtering method based on fast Fourier transform (FFT), and the morphological characteristics of the rough surface at Ra = 0.116 µm were described, and the simulated surface was consistent with the detected surface. The laser scanning confocal microscope (LSCM) and scanning electron microscope (SEM) were used for inspection, and the analysis showed that the main removal forms of the enhanced particles were broken, fractured, and pulled out. The surface defects were cracks, pits, and burrs, and the subsurface damages were voids, cracks, and pits.

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Abbreviations

n :

Spindle speed (rpm)

f :

Feed rate (mm/min)

a p :

Grinding depth (mm)

ρ :

Density (kg·m−3)

σ :

Equivalent stress of the material (MPa)

σ 0 :

Initial yield strength (Mpa)

A :

Original yield stress at quasi-static (MPa)

B :

Hardening modulus (MPa)

C :

Coefficient related to the strain rate

a :

Hardening exponent

b :

Thermal softening coefficient

T 0 :

Initial temperature (°C)

T m :

Melting temperature of the material (°C)

d 1-d 5 :

Failure coefficients

σ 1-σ 3 :

Principal stress (MPa)

σ 4 :

Failure stress of SiC particles (MPa)

μ n0 :

Nominal displacement (µm)

Gf I :

The type I fracture energy (J/m2)

σ I tu :

The critical stress for type I fracture (MPa)

G 0 :

The shear modulus of material failure

e ck nn :

The crack extension strain

R a :

Surface roughness—arithmetic mean roughness (µm)

R q :

Surface roughness—root mean square roughness (µm)

G :

Power spectral density

G Z :

Power spectral density function

α 2 :

Standard deviation of the height distribution

β x :

Autocorrelation lengths in the X directions respectively

β y :

Autocorrelation lengths in the Y directions respectively

N :

Sampling length in the X-axis direction

M :

Sampling length in the Y-axis direction

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Acknowledgments

This work was supported by the National Natural Science Foundation of China (51905083) and the Project of Natural Science Foundation of Liaoning Province (2022-MS-375).

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Authors and Affiliations

  1. School of Mechanical Engineering and Automation, Liaoning University of Technology, Jinzhou, 121001, China

    Xunyu Yin, Qi Gao, Ye Chen, Tianyang Cui & Ke Zhang

  2. Institute of Metal Research, Chinese Academy of Science, Shenyang, 110016, China

    Quanzhao Wang

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  1. Xunyu Yin
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  2. Qi Gao
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  4. Ye Chen
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Corresponding author

Correspondence to Qi Gao.

Additional information

Qi Gao is an Associate Professor at Liaoning University of Technology. He received a doctorate in Mechanical Engineering from Northeastern University. His research interests include micro precision process, digital manufacturing.

Xunyu Yin is a graduate student at Liaoning University of Technology. He received a bachelor’s degree in mechanical engineering from the Qingdao University of Science and Technology. His research interests are micro-scale grinding and composite materials machining.

Quanzhao Wang works in the Institute of Science. He received a doctorate in the Institute of Metal Research, Chinese Academy of Science. His research interests include materials processing engineering and digital manufacturing.

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Yin, X., Gao, Q., Wang, Q. et al. Study on micro-grinding mechanism and surface and subsurface quality of 20 vol% SiCp/Al composites. J Mech Sci Technol 37, 341–353 (2023). https://doi.org/10.1007/s12206-022-1233-0

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  • DOI: https://doi.org/10.1007/s12206-022-1233-0

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