Finite element analysis of ultrasonic assisted milling of SiCp/Al composites

Xiang, Daohui; Shi, Zhanli; Feng, Haoren; Wu, Bangfu; Zhang, Zhimeng; Chen, Yanbin; Niu, Xuming; Zhao, Bo

doi:10.1007/s00170-019-04542-z

Cited by 33 publications

(9 citation statements)

References 20 publications

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“…Owing to a series of excellent properties, including lightweight, superior wear resistance, and small thermal expansion coefficient, SiC p /Al composite thin-walled workpieces have been employed in a wide range of applications, such as automobiles, electronics, weapons, and aerospace. 1,2 However, the thin-walled workpieces still show some shortcomings during machining, such as poor rigidity and high material removal area. In addition, because of the presence of SiC particles, the processing mechanism of composites is different from that of single metal material.…”

Section: Introductionmentioning

confidence: 99%

Experimental study on cutting parameters and machining paths of SiC_p/Al composite thin-walled workpieces

Liu

Huang

Jiao

et al. 2020

Advanced Composites Letters

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Thin-walled workpieces of silicon carbide particle-reinforced aluminum matrix (SiCp/Al) composites with outstanding properties have been widely applied in many fields, such as automobile, weapons, and aerospace. However, the thin-walled workpieces exhibit poor rigidity, large yield ratio, and easily deform under the cutting force and cutting heat during the machining process. Herein, in order to improve the processing efficiency and precision of higher volume fraction SiCp/Al composite thin-walled workpieces, the influence of different high-speed milling parameters and machining paths on the edge defects is analyzed. The results reveal that the cutting force initially increased and then decreased with the cutting speed. Besides, the cutting force steadily increased with radial cutting depth and feed per tooth, but the influence of feed per tooth is less than radial cutting depth. After up-milling cut-in and cut-out processing and down-milling cut-out processing, the cut-in end of the workpiece exhibited higher breakage and obvious edge defects. However, the workpiece edges remained intact after down-milling cut-in processing. In conclusion, a higher cutting speed, a smaller radial cutting depth, and moderate feed per tooth are required to decrease the cutting force during the milling of SiCp/Al composite thin-walled workpiece. Furthermore, down-milling cut-in processing mode can reduce the edge defects and improve the processing efficiency and precision of the workpiece.

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Section: Introductionmentioning

confidence: 99%

Experimental study on cutting parameters and machining paths of SiC_p/Al composite thin-walled workpieces

Liu

Huang

Jiao

et al. 2020

Advanced Composites Letters

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“…SiC p /Al is a composite material with high specific stiffness, specific strength, and thermal conductivity, and a low thermal expansion coefficient. Therefore, it is widely used in precision optical instruments, advanced weapons, and the aerospace field [1][2][3][4]. In the aerospace field, SiC p / Al is widely used in optical structure components and electronic packaging systems.…”

Section: Introductionmentioning

confidence: 99%

Face Grinding Surface Quality of High Volume Fraction SiCp/Al Composite Materials

Zhao

Gong

Liang³

et al. 2021

Chin. J. Mech. Eng.

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The existing research on SiCp/Al composite machining mainly focuses on the machining parameters or surface morphology. However, the surface quality of SiCp/Al composites with a high volume fraction has not been extensively studied. In this study, 32 SiCp/Al specimens with a high volume fraction were prepared and their machining parameters measured. The surface quality of the specimens was then tested and the effect of the grinding parameters on the surface quality was analyzed. The grinding quality of the composite specimens was comprehensively analyzed taking the grinding force, friction coefficient, and roughness parameters as the evaluation standards. The best grinding parameters were obtained by analyzing the surface morphology. The results show that, a higher spindle speed should be chosen to obtain a better surface quality. The final surface quality is related to the friction coefficient, surface roughness, and fragmentation degree as well as the quantity and distribution of the defects. Lower feeding amount, lower grinding depth and appropriately higher spindle speed should be chosen to obtain better surface quality. Lower feeding amount, higher grinding depth and spindle speed should be chosen to balance grind efficiently and surface quality. This study proposes a systematic evaluation method, which can be used to guide the machining of SiCp/Al composites with a high volume fraction.

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“…Using ABAQUS finite element software, Li et al [ 5 ] established a two-dimensional simulation model of single particles, homogeneous materials, and multiple particles as well as the process of particle rupture in the processing of a large number of SiCp/Al composites under various processing parameters and investigated the temperature change. According to Xiang et al [ 6 ], since the processing parameters are highly associated with the surface properties, a finite element simulation analysis of the processing of SiC particles was performed to investigate the effect of various ultrasonic amplitudes on the surface properties of SiCp/Al materials. A comparative study was carried out to confirm the accuracy of ULTM and existing machining theory and simulation.…”

Section: Introductionmentioning

confidence: 99%

Study on the High-Speed Milling Performance of High-Volume Fraction SiCp/Al Composites

et al. 2021

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Compared with other materials, high-volume fraction aluminum-based silicon carbide composites (hereinafter referred to as SiCp/Al) have many advantages, including high strength, small change in the expansion coefficient due to temperature, high wear resistance, high corrosion resistance, high fatigue resistance, low density, good dimensional stability, and thermal conductivity. SiCp/Al composites have been widely used in aerospace, ordnance, transportation service, precision instruments, and in many other fields. In this study, the ABAQUS/explicit large-scale finite element analysis platform was used to simulate the milling process of SiCp/Al composites. By changing the parameters of the tool angle, milling depth, and milling speed, the influence of these parameters on the cutting force, cutting temperature, cutting stress, and cutting chips was studied. Optimization of the parameters was based on the above change rules to obtain the best processing combination of parameters. Then, the causes of surface machining defects, such as deep pits, shallow pits, and bulges, were simulated and discussed. Finally, the best cutting parameters obtained through simulation analysis was the tool rake angle γ0 = 5°, tool clearance angle α0 = 5°, corner radius r = 0.4 mm, milling depth ap = 50 mm, and milling speed vc= 300 m/min. The optimal combination of milling parameters provides a theoretical basis for subsequent cutting.

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Finite element analysis of ultrasonic assisted milling of SiCp/Al composites

Cited by 33 publications

References 20 publications

Experimental study on cutting parameters and machining paths of SiC_p/Al composite thin-walled workpieces

Experimental study on cutting parameters and machining paths of SiC_p/Al composite thin-walled workpieces

Face Grinding Surface Quality of High Volume Fraction SiCp/Al Composite Materials

Study on the High-Speed Milling Performance of High-Volume Fraction SiCp/Al Composites

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Finite element analysis of ultrasonic assisted milling of SiCp/Al composites

Cited by 33 publications

References 20 publications

Experimental study on cutting parameters and machining paths of SiCp/Al composite thin-walled workpieces

Experimental study on cutting parameters and machining paths of SiCp/Al composite thin-walled workpieces

Face Grinding Surface Quality of High Volume Fraction SiCp/Al Composite Materials

Study on the High-Speed Milling Performance of High-Volume Fraction SiCp/Al Composites

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Experimental study on cutting parameters and machining paths of SiC_p/Al composite thin-walled workpieces

Experimental study on cutting parameters and machining paths of SiC_p/Al composite thin-walled workpieces