Study On 3D Milling Simulation Of SiCp/Al Composites

SiCp / Al composite is a kind of particle reinforced metal matrix composite with high specific strength, little thermal deformation, excellent dimensional stability, good conductive performance, good abrasion resistance at high temperature, anti-aging and stable chemical performance and many other advantages. Therefore, the material have been widely used in aerospace, automotive, electronic packaging, sports equipment and medical equipment industries. But when machining, the high strength reinforced phase of SiCp particles make the tool wear serious. And the phenomenon of particle cracking and pulling out lead to the result that the quality of the machined surface declines seriously. These problems need to be solved urgently. Using finite element simulation method can provide an effective and low cost method to solve the problem by simulating the process. At present, the simulation on the machining process of the materials at home and abroad has gradually expanded, but basic problems have not been solved very well. The large finite element analysis software ABAQUS was used to establish various forms of model and Simulation of SiCp / Al composites, and the verification of the results was given. The main research contents are as follows:1、 The Johnson-Cook constitutive equation of SiCp/Al composites was set in the study. A series of basic materials testing were conducted, including quasi static compression test, split Hopkinson pressure bar test and quasi orthogonal cutting test. Static and dynamic mechanical properties of Al6063 matrix and different volume fraction of SiCp / Al composites were studied. Finally, the J-C constitutive equation suitable for the material was concluded.2、 With the application of ABAQUS 6.11, various types of 3D model(equivalent homogeneous model, tie connectionist models and cohesive element connectionist models) were established, and dynamic compression simulation was carried out on the material. Enhancement of mechanics performance of particle reinforced metal matrix composite material was studied, and the experimental results were compared with simulation results. A precise representation of material mechanical properties was confirmed from the three established models, namely, the equivalent homogeneous model.3、 The key technology in milling simulation was analyzed, including: multiphase modeling of workpiece in three dimension, milling model selection, material failure criteria, cutting chip separation criterion and method of separation, chip-tool contact and friction model. A 3D model in consideration of details of milling cutter and varying cutting thickness was established and simulated. Distribution of stress on theworkpiece was analyzed, as well as the simulation results of milling force.4、 Analysis of periodic change of cutting thickness in the milling process and tillage plough effect, with which milling test data of various volume fractions SiCp / Al composite was collected. The influence of the three factors(DOC, Feeding speed and cutting speed) on cutting force was researched, and the data was compared with the simulation results.