Numerical and experimental analysis of machining of Al (20 vol% SiC) composite by the use of ABAQUS software

Fathipour, Morteza; Yousefi, Reza

doi:10.1002/mawe.201300959

Cited by 39 publications

(22 citation statements)

References 7 publications

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“…The maximum stresses and computational time as a function of element number are shown, Figure . As can be seen, the computational time increases with increasing the number of elements . The computational time increases drastically when the element number exceeds 34235.…”

Section: Resultsmentioning

confidence: 88%

Modeling and experimental analysis in lifespan of a precision epoxy resin mold

Kuo

Chiang

2016

Materialwissenschaft Werkst

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Micro-hot embossing is a highly effective process for fabricating micro-devices with microfeatures in polymeric materials. One of the most troublesome problems in precision machinery industry is the time and expense needed to produce a mold for microreplication. Epoxy resin mold has been successfully employed for microreplication using micro-hot embossing. However, the junction of the groove and sprue of the backing plate has serious local stress concentration, leading to the reduction of lifespan of a precision epoxy resin mold during the micro-hot embossing molding. This work presents an effective method for enhancing the lifespan of a precision epoxy resin mold using reduction of local stress concentration. The numerical models were developed for predicting the maximum stress using ANSYS software. The ANSYS simulations have been carried out and the predicted results show good agreement with experimental tests. The junction of the groove and sprue of the backing plate was machined with chamfer to revaluate lifespan of the epoxy resin mold using micro-hot embossing molding. Micro-hot embossing verification test showed that the lifespan of epoxy resin mold with chamfer is about 2.2 times that of the conventional epoxy resin mold.

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Section: Resultsmentioning

confidence: 88%

Modeling and experimental analysis in lifespan of a precision epoxy resin mold

Kuo

Chiang

2016

Materialwissenschaft Werkst

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“…Thus, particles are only simulated by tied together with the matrix material which enables their initial displacements at the interface area are both equal to zero rather than constructing an artificial layer in interface when modelling interface properties. The interfacial de-bonding can be achieved through matrix material failure [21]. The MMCs cutting behaviour is significantly affected by the cutting parameters and the location of particles relative to the position of cutting tool.…”

Section: Integrated Modelling and Analysis Of Mmcs Machiningmentioning

confidence: 99%

Investigation on the material removal and surface roughness in ultraprecision machining of Al/B4C/50p metal matrix composites

Niu

Cheng

2019

Int J Adv Manuf Technol

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Metal matrix composites (MMCs) are increasingly applied in various engineering industries because of their distinct physical and mechanical properties. While the precision machining of MMCs is less understood due to their complex microstructure and poor machinability, a comprehensive scientific understanding on their machining mechanics and the associated surface generation mechanisms is of great importance particularly for industrial scale applications of MMCs. This paper presents a simulation and experimental-based holistic investigation on cutting mechanics, material removal and surface roughness in ultraprecision machining of MMCs. B 4 C/Al2024 is selected as the targeted MMC material in this research. The thermal-mechanical-tribological integrated modelling and analysis are presented to investigate the effects of cutting speed, feed rate and depth of cut (DOC) on the material removal, chip formation mechanics and surface generation process. The simulation results indicate that the machined surface roughness in precision machining of particle reinforced MMCs can be reduced by increasing the cutting speed and decreasing the depth of cut. The surface flow waviness decreases, which contributes to a higher surface quality, while machining with a smaller feed rate. The well-designed machining trials are conducted under the same cutting conditions and process variables as those in simulations, which perform a good agreement with simulation results.

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“…Furthermore, simplified assumptions on SiC particles, such as setting particles as linear elastomers, arranging particle shape as sphere, assigning uniform particle size and distribution, etc. [13][14][15][16], have been widely adopted in previous FE simulations, which inevitably deteriorate the accuracy of prediction results. For instance, stress pattern built in the vicinity of reinforcements are significantly different for spherical and polygon particles, which may also result in different machining behaviors of the composites.…”

Section: Introductionmentioning

confidence: 99%

Finite Element Investigation of the Influence of SiC Particle Distribution on Diamond Cutting of SiCp/Al Composites

Zhang

et al. 2020

Nanomanuf Metrol

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Characteristics of internal microstructures have a strong impact on the properties of particulate reinforced metal composites. In the present work, we perform finite element simulations to elucidate fundamental mechanisms involved in the ultra-precision orthogonal cutting of aluminum-based silicon carbide composites (SiCp/Al), with an emphasis on the influence of particle distribution characteristic. The SiCp/Al composite with a particle volume fraction of 25 vol% and a mean particle size of 10 μm consists of randomly distributed polygon-shaped SiC particles, the elastic deformation and brittle failure of which are described by the brittle cracking model. Simulation results reveal that in addition to metal matrix tearing, cutting-induced particle deformation in terms of dislodging, debonding, and cracking plays an important role in the microscopic deformation and correlated machining force variation and machined surface integrity. It is found that the standard deviation of particle size to the mean value has a strong influence on the machinability of microscopic particle–tool edge interactions and macroscopically observed machining results. The present work provides a guideline for the rational synthesis of particulate-reinforced metal composites with high machinability.

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Numerical and experimental analysis of machining of Al (20 vol% SiC) composite by the use of ABAQUS software

Cited by 39 publications

References 7 publications

Modeling and experimental analysis in lifespan of a precision epoxy resin mold

Modeling and experimental analysis in lifespan of a precision epoxy resin mold

Investigation on the material removal and surface roughness in ultraprecision machining of Al/B4C/50p metal matrix composites

Finite Element Investigation of the Influence of SiC Particle Distribution on Diamond Cutting of SiCp/Al Composites

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