A model for force prediction in grinding holes of SiCp/Al composites

Lu, Shiqi; Gao, Hang; Bao, Yan; Xu, Qihao

doi:10.1016/j.ijmecsci.2019.06.025

Cited by 34 publications

(10 citation statements)

References 37 publications

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“…The average error between the predicted and experimental values of the total grinding force of the model within this study's experimental parameters is 7.06%. Compared with the literature [39,40,59,60], the model's prediction error is within the acceptable range, and the predicted result of the model agrees well with the experimental value. 18.…”

Section: Model Validation Test Settingssupporting

confidence: 71%

“…6a. According to the literature [39], the tangential and normal forces acting on the contact area can be expressed as:…”

Section: Plastic Deformation Force Of Matrixmentioning

confidence: 99%

“…Cong et al [37,38] presented a force model of RUM for carbon fiber reinforced plastics (CFRP) composites for both brittle fracture and ductile-brittle transition. The grinding force model of SiCp/Al composites, considering the plastic deformation, brittle fracture, and debonding, was first proposed by Bao et al [39]. Zhou et al [40] divided the grinding force into side grinding force and end grinding force for grinding SiCp/Al composites.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Modeling for Ultrasonic Vibration-assisted Helical Grinding of SiC particle-reinforced Al-MMCs

Li¹,

Yuan

Gao³

et al. 2023

Preprint

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Silicon carbide (SiC) particle-reinforced aluminum matrix (SiCp/Al) composites have continuously increased applications in abundant industries due to their superior mechanical properties. However, such composites have issues achieving desired machinability and quality standard due to the presence of SiC particles which is the main hindrance to their applications. In this paper, the methodology of ultrasonic vibration-assisted helical grinding (UVHG) of SiCp/Al composites has been applied to achieve to desired quality and efficiency for such composites. Then a mechanical cutting force model was developed to predict grinding forces. The grinding force was separated into friction force, plastic deformation force, and fracture force on account of the material removal mechanism. The undeformed chip thickness and cross-sectional area were calculated for the grinding force of a single diamond abrasive grit and then extended to the whole tool. By considering the acoustic softening effect of reduction of deformation stress caused by ultrasonic vibration, the acoustic softening coefficient was first proposed in the model to correct the impact of the ultrasonic vibration for properties of SiCp/Al composites. The experimental machining (UVHG) was carried out considering the different groups of experiments. The experimental results found agreed with the predicted values of cutting forces. The prediction deviation of the model was 7.06%, which could provide further guidance for the grinding process optimization of SiCp/Al composites. The novel cutting force predicted model and proposed machining methodology could be applied to machining SiCp/Al composites at the industry level and further research work.

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Section: Model Validation Test Settingssupporting

confidence: 71%

“…6a. According to the literature [39], the tangential and normal forces acting on the contact area can be expressed as:…”

Section: Plastic Deformation Force Of Matrixmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Modeling for Ultrasonic Vibration-assisted Helical Grinding of SiC particle-reinforced Al-MMCs

Li¹,

Yuan

Gao³

et al. 2023

Preprint

View full text Add to dashboard Cite

show abstract

“…Surface damages such as debonding of reinforcement from the metal matrix cracked reinforcement, particle breakage, and cracks at the surface are the reason for the increased forces while grinding using the SiC wheel [192]. Considering the plastic deformation force of the matrix material, the friction force between grits and workpiece material, and the removal force of SiC particles, a grinding force model suitable for grinding holes of SiC p / Al composites with high-volume fractions was established by Lu et al [193]. The effect of the grinding parameters on the grinding force, as shown in Fig.…”

Section: Surface Grindingmentioning

confidence: 99%

A review on conventional and nonconventional machining of SiC particle-reinforced aluminium matrix composites

Chen

2020

Adv. Manuf.

105

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Among the various types of metal matrix composites, SiC particle-reinforced aluminum matrix composites (SiC p /Al) are finding increasing applications in many industrial fields such as aerospace, automotive, and electronics. However, SiC p /Al composites are considered as difficult-to-cut materials due to the hard ceramic reinforcement, which causes severe machinability degradation by increasing cutting tool wear, cutting force, etc. To improve the machinability of SiC p /Al composites, many techniques including conventional and nonconventional machining processes have been employed. The purpose of this study is to evaluate the machining performance of SiC p /Al composites using conventional machining, i.e., turning, milling, drilling, and grinding, and using nonconventional machining, namely electrical discharge machining (EDM), powder mixed EDM, wire EDM, electrochemical machining, and newly developed high-efficiency machining technologies, e.g., blasting erosion arc machining. This research not only presents an overview of the machining aspects of SiC p /Al composites using various processing technologies but also establishes optimization parameters as reference of industry applications.

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“…where P 0 is defined as the experiential suitability factor calculated via the experiments. The frictional coefficient µ is clarified as [44].…”

Section: Frictional Forcementioning

confidence: 99%

Model for Predicting the Micro-Grinding Force of K9 Glass Based on Material Removal Mechanisms

et al. 2020

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K9 optical glass has superb material properties used for various industrial applications. However, the high hardness and low fracture toughness greatly fluctuate the cutting force generated during the grinding process, which are the main factors affecting machining accuracy and surface integrity. With a view to further understand the grinding mechanism of K9 glass and improve the machining quality, a new arithmetical force model and parameter optimization for grinding the K9 glass are introduced in this study. Originally, the grinding force components and the grinding path were analyzed according to the critical depth of plowing, rubbing, and brittle tear. Thereafter, the arithmetical model of grinding force was established based on the geometrical model of a single abrasive grain, taking into account the random distribution of grinding grains, and this fact was considered when establishing the number of active grains participating in cutting Nd-Tot. It should be noted that the tool diameter changed with machining, therefore this change was taking into account when building the arithmetical force model during processing as well as the variable value of the maximum chip thickness amax accordingly. Besides, the force analysis recommends how to control the processing parameters to achieve high surface and subsurface quality. Finally, the force model was evaluated by comparing theoretical results with experimental ones. The experimental values of surface grinding forces are in good conformity with the predicted results with changes in the grinding parameters, which proves that the mathematical model is reliable.

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A model for force prediction in grinding holes of SiCp/Al composites

Cited by 34 publications

References 37 publications

Modeling for Ultrasonic Vibration-assisted Helical Grinding of SiC particle-reinforced Al-MMCs

Modeling for Ultrasonic Vibration-assisted Helical Grinding of SiC particle-reinforced Al-MMCs

A review on conventional and nonconventional machining of SiC particle-reinforced aluminium matrix composites

Model for Predicting the Micro-Grinding Force of K9 Glass Based on Material Removal Mechanisms

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