Finite Element Investigation of the Influence of SiC Particle Distribution on Diamond Cutting of SiCp/Al Composites
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ORIGINAL ARTICLE
Finite Element Investigation of the Influence of SiC Particle Distribution on Diamond Cutting of SiCp/Al Composites Shijin Lu1 · Zengqiang Li1,2 · Junjie Zhang1,2 · Jianguo Zhang3 · Xiaohui Wang4 · Yongda Yan1 · Tao Sun1 Received: 5 June 2020 / Revised: 30 July 2020 / Accepted: 2 September 2020 © The Author(s) 2020
Abstract 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 ultraprecision 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, cuttinginduced 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. Keywords SiCp/Al composites · Orthogonal cutting · Particle–tool interaction · Particle distribution · FE simulation
1 Introduction Aluminum-based silicon carbide composites (SiCp/Al) have been widely used in the aerospace, automotive, machinery, and electronics industries for their unique physical and mechanical properties [1–3]. While mechanical machining is normally required to achieve desired shapes with considerable accuracy, recently cutting technique has also been proposed to process SiCp/Al composites for its high geometrical accuracy and high efficiency [4]. However, the * Junjie Zhang [email protected] 1
Center for Precision Engineering, Harbin Institute of Technology, Harbin 150001, China
2
Technology and Innovation Research Center of Jiangyan Economic Development Zone, Taizhou 225300, China
3
State Key Laboratory of Digital Manufacturing Equipment and Technology, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
4
School of Mechanical Engineering, University of Jinan, Jinan 250022, China
poor synergetic deformation behavior between hard–brittle SiC reinforcement and soft–ductile Al matrix leads to low machinability of SiCp/Al in cutting process. In particular for the ultra-precision diamond cutting with depths of cut (DOCs) comparable to particle sizes, the underlying machining mechanisms of SiCp/Al are complex due
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