The Simulation And Experimental Research On SiCp/Al Composite

SiCp/Al composites (aluminum alloys reinforced with SiC particles) are classified asthe typical difficult-to-machine materials, which are widely used in aerospace, automobileand electronics due to their excellent characteristics such as high specific strength, specificstiffness, anti-fatigue, resistant corrosion, low thermal coefficient of expansion, favorabledimensional stability and thermal conduction, etc. and many other excellent mechanicalproperties and physical properties. However, the existence of SiC reinforced particles resultto serious tool wear, premature tool failure, surface defects, etc. Therefore, we can makefull use of finite element simulation technology (FEM) to predict cutting forces andoptimize cutting parameters. But there is seldom research on SiCp/Al composites by usingFEM at home and abroad. In this paper, the two-dimensional finite element modelingtechnology of the cutting process and milling process for SiCp/Al composites andaluminum are investigated by using ABAQUS explicit. Then the variation of forces withvarious cutting speed and feed rate is studied and compared with experimental data.Following are the main content：1. In order to understand the formation mechanism of chip and machined surface, thetwo-dimensional finite element modeling technology of the cutting process for SiCp/Alcomposites are investigated by using ABAQUS explicit. The actual microstructure ismodeled by a multi-phase modeling approach with a circular SiC reinforcement phaserandomly distributed in a6061aluminum alloy matrix phase, while the stress and straindistribution are discussed.2. The cutting forces vs. time due to the interaction between cutting tools and SiCparticles in the cutting process are analyzed not only in simulation but also by experiment.Finally, surface defects including particles debonding, small pits, raised particles and tracesof ploughing are predicted and verified by the experimental surface topography.3. The effect of volume fraction of SiC particles is studied by simulating theorthogonal cutting process of three SiCp/Al composites with multiplied increasing volumefraction of SiC reinforcement particles.4. A multi-phase finite element model has been developed by using of ABAQUSexplicit software and is used to simulate milling of high volume fraction of6063Al/SiCp composite and6063Al. The stress and strain distribution in three deformation zones ofaluminum and SiCp/Al composites are analyzed and compared.5. The variation of milling forces with various cutting speed and feed rate is studiedand compared with experimental data. It is found that both the milling speed and feed ratehave significant effect on the milling force.6. Made a conclusion of the origin and composition of cutting force when machiningparticulate reinforced metal matrix composite and compared it with homogeneousmaterials.