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Prediction and Verification of Cutting Force in Machining of SiCp/Al Composites Based on Dynamic Mechanical Characteristics of Cutting Deformation Zone

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Abstract

Metal matrix composites (MMCs) reinforced by ceramic particles have been gradually applied in modern industry because of their excellent mechanical characteristics. However, the addition of high hardness particles also produces a significant challenge for machining of MMCs. Cutting force characterizes the dynamic mechanical characteristics of cutting deformation zone by reflecting the interaction of tool-workpiece, which is of great significance to describe the machinability of MMCs. This paper aims to propose a geometric model of cutting force to predict the cutting force and monitor the cutting state during machining of SiCp/Al composites. The shear deformation force, friction force in tool-chip interface and ploughing force in tool-workpiece interface, corresponding to shear deformation zone (plastic deformation of Al matrix mainly), fraction zone (tool-chip interaction) and ploughing zone (tool-workpiece interaction and fracture and debonding of SiC particles) were considered in predicted model. Meanwhile, the influence of tool cutting edge radius was considered. The results obtained by systematic cutting experiment with different cutting conditions were compared with predicted results, and the maximum error between predicted and measured value was within 12%, indicating the validity of predicted model in machining of SiCp/Al composites. With the increase of cutting depth (0.1 mm-1.5 mm), the roughness of machined surface increased from 149 to 377 nm, which can be explained by a larger deformation resistance caused by a deeper cutting depth. In addition, the applicability of the proposed model under different volume fraction of SiCp/Al composites were studied, and the maximum error between predicted and measured value is within 5%.

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Abbreviations

R :

Average diameter of particles (μm)

V p :

Volume fraction of SiC particle (%)

a p :

Cutting depth (mm)

f :

Feed rate (mm/rev)

v c :

Cutting speed (m/min)

γ :

Rake angle (degree)

\({r}_{\varepsilon }\) :

Tool nose radius (mm)

\({r}_{z}\) :

Cutting edge radius (mm)

\({\upkappa }_{r}\) :

Approach angle (degree)

\({\kappa }_{r1}\) :

Departure angle (degree)

\({\kappa }_{r}*\) :

Effective approach angle (degree)

\({\tau }_{s}\) :

Shear flow stress of material (MPa)

\({F}_{OC}\) :

Main force (N)

\({F}_{X}\) :

Radial force (N)

\({F}_{Y}\) :

Feed force (N)

\({F}_{Z}\) :

Main cutting force (N)

ε :

Equivalent shear strain

\(\dot{\varepsilon }\) :

Strain state (s−1)

T :

Absolute temperature (℃)

\({T}_{r}\) :

Ambient temperature (℃)

\({T}_{m}\) :

Melting temperature (℃)

φ :

Shear angle (degree)

μ :

Friction angle (degree)

\({\mu }_{3-bodv}\) :

Coefficient of rolling friction

l :

Contact length (mm)

h :

Contact width (mm)

a :

Initial crack length (mm)

δ :

Angle between the cutting force and the cutting direction (degree)

\({\delta }_{p0}\) :

Critical penetration depth (mm)

A :

Contact area in tool-chip interface (mm2)

\({A}_{sic}\) :

Contact area between SiC particles of chip bottom and rake face (mm2)

u :

Energy consumed by fracture and debonding of individual particle (J)

G :

Shear modulus of material before fracture (MPa)

w :

Initial crack width (mm)

\({\tau }_{crit}\) :

Limit of shear stress (MPa)

\({\tau }_{ea}\) :

Shear stress keeping adhesion (MPa)

\({\sigma }_{0}\) :

Tensile stress of material (MPa)

\({\sigma }^{*}\) :

Stress triaxiality

p :

Normal stress acting on chip (MPa)

\({\mu }_{f}\) :

Friction coefficient in Coulomb

d 1 …d 5 :

Fracture parameters

\(p,{e}_{\text{max}}^{ck}\) :

Material parameter

\({\varepsilon }_{m}^{\text{max}}\) :

Maximum effective separation

\({\tau }_{crit}\) :

Limit of shear stress (MPa)

\({F}_{I-x},{F}_{II-x},{F}_{III-x}\) :

Force components along the direction of cutting speed in three cutting deformation zones (N)

\({F}_{I-y},{F}_{II-y},{F}_{III-y}\) :

Force components along the direction of cutting feed in three cutting deformation zones (N)

\({F}_{I-z},{F}_{II-z},{F}_{III-z}\) :

Force components along the direction of cutting depth in three cutting deformation zones (N)

\({\varepsilon }^{f}\) :

Equivalent strain of fracture

\({\sigma }_{tu}^{I}\) :

Fracture stress of particles (MPa)

A,B,C,n,m :

J-C equation constants

b :

Cutting width (mm)

\({F}_{n}\) :

Normal force in rake face (N)

\({F}_{f}\) :

Friction force in the shear deformation zone (N)

\({F}_{s}\) :

Shear forces along shear plane (N)

\({F}_{\tau }\) :

Normal force perpendicular to the shear plane (N)

F g :

Friction in tool-chip interface (N)

F g 1 :

Friction force produced by SiC particles in tool-chip interface (N)

F g 2 :

Friction force produced by metallic matrix in tool-chip interface (N)

\({F}_{2-body}\) :

Sliding friction (N)

\({F}_{3-body}\) :

Rolling friction (N)

\({F}_{p}\) :

Normal force of ploughing (N)

\({F}_{t}\) :

Tangential force of ploughing (N)

\({F}_{N}\) :

Normal force on rake face produced by total reinforcement particles (N)

\({F}_{N1}\) :

Normal force on rake face produced by individual particle (N)

\({N}_{p}\) :

Number of reinforcement particles at tool-chip interface

Ф:

Fraction of particles involved in two-body abrasion (%)

\({\sigma }_{1},{\sigma }_{2},{\sigma }_{3}\) :

Main stress component (MPa)

\({G}_{c}\) :

Shear modulus of SiC (MPa)

\({e}_{nn}^{ck}\) :

Shear transfer coefficient

\({e}_{nn}^{ck}\) :

Initial strain of crack

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Acknowledgements

This work was supported by the National Natural Science Foundation of China (U19A20104), Micro-Nano and Ultra-Precision Key Laboratory of Jilin Province (20140622008JC), Science and Technology Development Projects of Jilin Province (20190201303JC).

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Authors and Affiliations

  1. Key Laboratory of Micro-Nano and Ultra-Precision Manufacturing of Jilin Province, School of Mechatronic Engineering, Changchun University of Technology, Changchun, 130012, China

    Jiakang Zhou, Jieqiong Lin, Mingming Lu, Yongsheng Du & Chao Wang

  2. School of Mechanical and Aerospace Engineering, Jilin University, 130022, Changchun, China

    Xiaoqin Zhou

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  1. Jiakang Zhou
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Contributions

Jiakang Zhou: Conceptualization, Writing- Original draft preparation, Methodology, Software, Validation, Data curation. Jieqiong Lin: Conceptualization, Funding acquisition, Supervision. Mingming Lu: Investigation, Methodology, Validation, Writing—Review & Editing. Xiaoqin Zhou: Conceptualization and Supervision. Yongsheng Du: Visualization, Investigation, Data curation, Formal Analysis. Chao Wang: Methodology, Data curation, Formal analysis.

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Correspondence to Jieqiong Lin or Mingming Lu.

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Zhou, J., Lin, J., Lu, M. et al. Prediction and Verification of Cutting Force in Machining of SiCp/Al Composites Based on Dynamic Mechanical Characteristics of Cutting Deformation Zone. Appl Compos Mater 28, 2105–2126 (2021). https://doi.org/10.1007/s10443-021-09958-z

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