Finite element and experimental analysis of machinability during machining of high-volume fraction SiCp/Al composites

• Published in: International journal of advanced manufacturing technology Vol. 91; no. 5-8; pp. 1935 - 1944
• Main Authors: Zhou, L., Cui, C., Zhang, P.F., Ma, Z.Y.
• Format: Journal Article
• Language: English
• Published: London Springer London 01.07.2017; Springer Nature B.V
• Subjects: Alloys; Aluminum base alloys; Brittleness; CAE) and Design; Composite materials; Computer simulation; Computer-Aided Engineering (CAD; Constitutive models; Cutting parameters; Damage; Damage assessment; Elastic properties; Engineering; Finite element method; Industrial and Production Engineering; Information dissemination; Inhomogeneity; Irregular particles; Machinability; Machining; Mathematical models; Mechanical Engineering; Mechanical properties; Mechanics (physics); Media Management; Morphology; Original Article; Particulate composites; Residual stress; Silicon carbide; Stress concentration; Surface finish; Surface roughness; Machinability; Composites; Orthogonal cutting; Finite element simulation
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-016-9933-1

The machinability, including machined surface, edge quality, and the distribution of the subsurface residual stress, was studied during the orthogonal cutting of high-volume fraction SiCp/Al composites by both finite element analysis and experiments. The effect of cutting parameters on surface roughness, sizes of edge breakout, and residual stress were investigated. The elastic-plastic constitutive model and Johnson–Cook damage model for the Al alloy matrix, and the elastic-brittle failure for SiC particle were implemented in the mechanical properties of composites during the cutting simulation. The results indicate that the surface morphology is primarily dependent on the fracture models of SiC particles, and the formation of the negative shear plain is the main reason of edge breakout. Due to the inhomogeneity in the composites, the distribution of surface and subsurface residual stress is not uniform, and the high residual stress was distributed in the interface between irregular particles and matrix. The average value of residual stress of SiC particle is similar to that of the matrix. The predicted machined surface morphology and edge breakout sizes correlated well with the experimental observation. This study highlights the important role of the fracture model of SiC particles on surface finish and the edge quality. It provides useful information for better understanding of the mechanics in machining of the SiCp/Al composites.