Investigation and simulation based on mesoscopic model of SiCp/Al composites during precision machining: deformation mechanism and surface quality

Abstract

Ceramic particle-reinforced metal matrix composites (PRMMCs) have been widely applied in modern industry with excellent mechanical characteristics. Meanwhile, the addition of high hardness reinforcements also produces a significant challenge for precision machining of PRMMCs and leads to poor machinability and higher time consumed in the subsequent surface treatment process. To investigate the machining mechanism of PRMMCs, a 2D mesoscopic-based finite element (FE) model reinforced with randomly distributed polygon particles was developed. Elastoplastic and failure behavior of aluminum alloy, high hard-brittle and fracture characteristics of reinforcements and particle-matrix-tool interactions were considered comprehensively. Systematic cutting experiments show that the proposed FE model accurately predicts deformation mechanism and surface quality of PRMMCs. Particle fracture and debonding are mainly determined by the stress distribution and strain value. Serrated chips primarily are formed along shear plane and accompanied with the generation and propagation of microcracks. In addition, cracks around particles are easier to propagate to chip root and promote the formation of segmented chips. Cutting depth significantly affects the surface quality, subsurface damage, and cutting force. Moreover, a proper cutting speed is beneficial to improve efficiency and machinability of PRMMCs. Keywords Ceramic particle • Metal matrix composites • Precision machining • Deformation mechanism • Finite element analysis AbbreviationsYield stress (MPa) t Tensile stress (MPa) cCompressive stress (MPa) 0

A Review on Machining SiCp/Al Composite Materials

“…It is believed that when processing SiCp/Al composite materials, SiC is removed through methods, such as crushing, debonding, fracture, shearing, pulling in, and pulling out. Zhou et al [ 11 ] proposed a deformation mechanism and surface quality finite element model that accurately predicted metal matrix composites (MMCs). They found that serrated chips mainly form along the shear plane, accompanied by the generation and propagation of microcracks.…”

A review of mesoscopic modeling and constitutive equations of particle-reinforced metals matrix composites based on finite element method

“…For instance, the application of materials is inseparable from mechanical processing, which typically involves precise cutting. The quality of the machined surface constitutes a crucial factor that impacts the actual properties of the material [ 8 ]. With the help of finite element simulation, the cutting model of PRMMCs can be established, and the stress-strain relationship, damage form and dynamic chip formation mechanism inside the material during cutting can be simulated from a microscopic perspective [ 9 , 10 ], so as to optimize the processing technology and improve the processing quality.…”

A study on surface finish of SiCp/Al composites machining

“…Cutting parameters have a great influence on the removal form of particles and the quality of the machined surfaces, so many scholars take cutting parameters as the research point. Zhou et al [11] predicted through the finite element model that the increase in cutting depth also increased the probability of particle fracture and debonding under the cutting path, *bradywang@hit.edu.cn; tele 0451-86415244; fax 0451-86415244 thus leading to the deterioration of surface quality. Diptikanta Das et al [12] believed that the setting of cutting depth and cutting speed seriously affects the quality of the machined surface.…”