Research On Cutting Parameters Simulation And Experiment Of SiCp/Al Composites

Silicon carbide particle reinforced aluminum matrix composites(SiCp/Al) have many excellent physical and mechanical properties such as high specific stiffness and high specific modules, high wear resistance, low thermal expansion, good dimensional stability, which make them widely be used in aerospace, automotive, electronic packaging and sports equipment and other fields. However, the presence of reinforced particles in SiCp/Al composites has led to poor machining performance, which has hampered the development and application of composite materials. Therefore, it is very important to study the machining process of SiCp/Al composites in order to make composite materials acquire the wider range of applications.The finite element basic idea, the finite element analysis basic steps and the finite element modeling technologies were investigated to simulate the cutting process of SiCp/Al composites correctly, this paper established two simulation models based on the finite element method by using the finite element analysis software ABAQUS, which included macro model that defined the overall characteristics of SiCp/Al composites and microscopic model that defined respectively the characteristics of SiC particles and Al matrix. Two models investigated the influence of cutting depth and cutting speed on cutting forces and analyzed the distribution of stress field. Simultaneously, on the basis of microscopic model, the chip formation process was simulated, the particles and the matrix stress distribution and tool-particle interactions were explored and machined surface defects were analyzed.In order to verify the correctness and effectiveness of the two simulation models, an experiment has been carried out by the turning SiCp/Al composites on the machine of CA6140 A.The results show that the trend of cutting curves generated from the experiment is consistent with two simulation models, which verifies the correctness of two finite element models.The research results show the cutting force increase with the increase of cutting depth and decrease slightly with the increase of cutting speed. Microscopic model simulation results can be found that firstly the von Mises stress of particle is evidently higher than that of Al alloy matrix, the maximum von Mises stress is located mainly at interfaces of the particles and matrix, secondly the failure of material begins from the gap around the particles, and finally the SiC particles debond from the matrix, the moving and rotating of SiC particles inside the matrix can both lead to the formation of surface defects.