Research On Cutting Force And Surface Quality Of Heating-assisted Cutting SiCp/Al Composite

Compared with traditional metal materials,SiCp/Al composite materials have excellent properties,such as high specific strength,high specific modulus,and small thermal expansion coefficient.They have been commercialized in aerospace,automotive industry,and electronic packaging.Because of the large amount of high-hardness SiC particles in the SiCp/Al composite material,the vibration force during the cutting process changes the cutting force greatly,resulting in difficult surface quality problems and increased processing costs.Heatassisted cutting has always been a research hotspot in the field of cutting processing technology.This method has unique advantages when processing some difficult-to-machine materials,but it also faces many problems that need to be solved.In this paper,the ABAQUS simulation software is used to establish the finite element cutting model of SiCp/Al composite materials.The microscopic stress distribution of the material is used to study the surface formation mechanism.Based on the cutting force generation mechanism,a heating-assisted milling SiCp/Al composite cutting force model was established,and a heating-assisted milling experiment was conducted,and the cutting force model was verified,and the influence of heating cutting parameters on milling force and machining surface quality was analyzed,Optimizing the processing parameters,providing a theoretical basis and technological basis for guiding the actual production.The main research contents are as follows:(1)Using ABAQUS finite element analysis software,based on the brittle cracking model,a heating-assisted cutting model with a microstructure was established.The influence of cutting parameters,material parameters(particle volume fraction and particle size)and heating temperature on cutting force was studied.The influence of material parameters on the stress distribution of the workpiece and the formation process of the machined surface of SiCp/Al composite materials were analyzed.The influence of the particle removal method on the quality of the processed surface with and without heating temperature was compared and analyzed.The results show that the increase in heating temperature reduces the mechanical properties of the material.The material softens and is cut by the tool under a low stress state,resulting in a significant reduction in cutting force and a reduction in particle damage,causing in a large number of particles being pressed into the matrix to form protrusions.(2)By analyzing the source of cutting force,considering the influence of temperature on material properties,the coefficient of effect of heating temperature on cutting force is proposed,and the theoretical model of cutting force for heating-assisted milling SiCp/Al composites is established.An experimental platform for overall heating-assisted milling was built,heatingassisted milling experiment was carried out,and the theoretical model of cutting force was verified.The influence mechanism and change rule of cutting parameters and heating temperature on cutting force were studied.The results show that the milling force is less affected by the milling speed and increases with the increase of the feed per tooth,milling width and milling depth.As the heating temperature is increased,the milling force is greatly reduced.(3)Orthogonal experimental scheme was designed,the whole heating assisted milling experiment of SiCp/Al composite was carried out,and the formation mechanism of machining surface defects was analyzed in combination with finite element simulation The range and importance of cutting parameters and heating temperature on surface roughness were studied using range and variance analysis methods.As a result,it was found that the feed per tooth had the greatest influence,and the rest were heating temperature,milling speed,milling depth and milling width.An empirical formula for surface roughness is established,with the minimum surface roughness as the optimization goal,the processing parameters are optimized,and the best combination of process parameters is obtained.