Top

The International Journal of Advanced Manufacturing Technology

Published in:

23-02-2024 | ORIGINAL ARTICLE

Study on the formation mechanism of surface defects in the processing of large particle SiCp/Al composites

Authors: Zhigao Chen, Bo Wang, Duo Li, Ziteng Li, Mingjun Chen

Published in: The International Journal of Advanced Manufacturing Technology | Issue 7-8/2024

Activate our intelligent search to find suitable subject content or patents.

search-config

AI-assisted search

Off

Abstract

Highly efficient machining of SiCp/Al composites is always a challenge due to their poor surface integrity. This paper aims to study the cutting mechanism considering the interaction between particles and reveals the removal process of SiC particles under different cutting parameters. Furthermore, a thorough analysis was conducted to examine the impact of SiC particles on cutting force, chip shape, and surface defects. The results indicate that the form of particle removal is determined by the relative position of the cutting path and SiC particles, which includes particle fracture, push-in, slip, and debonding. As the cutting depth increases, the cutting force also increases from 10.4 to 20.1 N, and the presence of SiC particles can cause significant fluctuations in the cutting force. In addition, an increase in cutting speed improves surface quality, and the chips primarily exhibit a block- and sheet-like shape. This study provides valuable insights into the removal mechanism and process research of SiCp/Al composites.

previous article Gradual error detection technique for non-destructive assessment of density and tensile strength in fused filament fabrication processes

next article Effect of beam defocusing on porosity formation mechanism in laser-MIG hybrid welded titanium alloy joints

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

über 102.000 Bücher
über 537 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Finance + Banking
Management + Führung
Marketing + Vertrieb
Maschinenbau + Werkstoffe
Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

inform now

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

über 67.000 Bücher
über 390 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Maschinenbau + Werkstoffe

Jetzt Wissensvorsprung sichern!

inform now

Available only for authorised users

Sahin Y (2003) Preparation and some properties of SiC particle reinforced aluminium alloy composites. Mater Des 24(8):671–679. https://doi.org/10.1016/S0261-3069(03)00156-0CrossRef

Teti R (2002) Machining of composite materials. CIRP Ann 51(2):611–634. https://doi.org/10.1016/S0007-8506(07)61703-XCrossRef

Dandekar CR, Shin YC (2012) Modeling of machining of composite materials: a review. Int J Mach Tool Manu 57:102–121. https://doi.org/10.1016/j.ijmachtools.2012.01.006CrossRef

Liu JW, Cheng K, Ding H, Chen SJ, Zhao L (2016) An investigation of surface defect formation in micro milling the 45% SiCp/Al composite. Procedia Cirp 45: 211–214. https://doi.org/10.1016/j.procir.2016.02.327

Yin GQ, Gong YD, Li YW, Li SJ, Zhou YG (2019) Modeling and evaluation in grinding of SiCp/Al composites with single diamond grain. Int J Mech Sci 163:105137. https://doi.org/10.1016/j.ijmecsci.2019.105137CrossRef

Yu WW, Chen J, Ming WW, An QL, Chen M (2021) Experimental and FEM study of cutting mechanism and damage behavior of ceramic particles in orthogonal cutting SiCp/Al composites. Ceram Int 47(5):7183–7194. https://doi.org/10.1016/j.ceramint.2020.11.072CrossRef

Cui YZ, Gao SR, Wang FJ, Hu QM, Xu C, Xu FX (2021) Study on the high-speed milling performance of high-volume fraction SiCp/Al composites. Materials 14(15):4143. https://doi.org/10.3390/ma14154143CrossRef

Chen YF, Zhang X (2021) Study on the cutting mechanism of SiCp/Al considering particle size and distribution. Int J Adv Manuf Technol 115(4):1211–1225. https://doi.org/10.1007/s00170-021-07225-wCrossRef

Zhang P, Yue X, Zhang Q, Zong CG, Lu W, Fang YX (2021) Investigation on the influence of SiC particle parameters on the machinability of SiCp/Al composite. Vacuum 191:110340. https://doi.org/10.1016/j.vacuum.2021.110340CrossRef

10.

Sandhiya YN, Thamizharasan MM, Subramanyam BA, Sekar KV, Kumar SS (2018) Finite element analysis of tool particle interaction, particle volume fraction, size, shape and distribution in machining of A356/SiCp. Mater Today 5(8):16800–16806. https://doi.org/10.1016/j.matpr.2018.06.006CrossRef

11.

Wang YF, Liao WH, Yang K, Chen WQ, Liu TT (2019) Investigation on cutting mechanism of SiCp/Al composites in precision turning. Int J Adv Manuf Technol 100:963–972. https://doi.org/10.1007/s00170-018-2650-1CrossRef

12.

Gad SI, Attia MA, Hassan MA, El-Shafei AG (2021) Predictive computational model for damage behavior of metal-matrix composites emphasizing the effect of particle size and volume fraction. Materials 14(9):2143. https://doi.org/10.3390/ma14092143CrossRef

13.

Paknia A, Pramanik A, Dixit AR, Chattopadhyaya S (2016) Effect of size, content and shape of reinforcements on the behavior of metal matrix composites (MMCs) under tension. J Mater Eng Perform 25:4444–4459. https://doi.org/10.1007/s11665-016-2307-xCrossRef

14.

Zhang P, Yue XJ, Zhang Q, Zong CG, Lu W, Fang YX (2021) Investigation on the influence of SiC particle parameters on the machinability of SiCp/Al composite. Vacuum 191:110340. https://doi.org/10.1016/j.vacuum.2021.110340CrossRef

15.

Laghari RA, Li JG, Wu YX (2020) Study of machining process of SiCp/Al particle reinforced metal matrix composite using finite element analysis and experimental verification. Materials 13(23):5524. https://doi.org/10.3390/ma13235524CrossRef

16.

Das D, Pradhan SK, Sahoo AK, Panda A, Satpathy MP, Samal C (2020) Tool wear and cutting force investigations during turning 15 wt% SiCp-Al 7075 metal matrix composite. Mater Today: Proc 26:854–859. https://doi.org/10.1016/j.matpr.2020.01.053CrossRef

17.

Zhang DN, Shangguan QQ, Xie CJ, Liu F (2015) A modified Johnson-Cook model of dynamic tensile behaviors for 7075–T6 aluminum alloy. J Alloys Compd 619:186–194. https://doi.org/10.1016/j.jallcom.2014.09.002CrossRef

18.

Shrot A, Bäker M (2012) Determination of Johnson-Cook parameters from machining simulations. Comput Mater Sci 52(1):298–304. https://doi.org/10.1016/j.commatsci.2011.07.035CrossRef

19.

Wang XM, Shi J (2013) Validation of Johnson-Cook plasticity and damage model using impact experiment. Int J Impact Eng 60:67–75. https://doi.org/10.1016/j.ijimpeng.2013.04.010MathSciNetCrossRef

20.

Akram S, Jaffery SHI, Khan M, Fahad M, Mubashar A, Ali L (2018) Numerical and experimental investigation of Johnson–Cook material models for aluminum (Al 6061-T6) alloy using orthogonal machining approach. Adv Mech Eng 10(9) https://doi.org/10.1177/1687814018797794

21.

Ducobu F, Rivière-Lorphèvre E, Filippi E (2017) On the importance of the choice of the parameters of the Johnson-Cook constitutive model and their influence on the results of a Ti6Al4V orthogonal cutting model. Int J Mech Sci 122:143–155CrossRef

22.

Tan YQ, Yang DM, Sheng Y (2009) Discrete element method (DEM) modeling of fracture and damage in the machining process of polycrystalline SiC. J Eur ceram soc 29(6):1029–1037. https://doi.org/10.1016/j.jeurceramsoc.2008.07.060CrossRef

23.

Fan YH, Xu YS, Hao ZP, Lin JQ (2022) Cutting deformation mechanism of SiCp/Al composites based on strain gradient theory. J Mater Process Technol 299:117345. https://doi.org/10.1016/j.jmatprotec.2021.117345CrossRef

24.

Li MJ, Wang ZL, Li W, Yang XJ (2022) Modeling and experimental study on tool-particle interaction and surface integrity in milling SiCp/Al metal matrix composites. P I Mech Eng 236(11):1535–1550. https://doi.org/10.1177/0954405422107777CrossRef

25.

Wierzbicki T, Bao YB, Lee YW, Bai YL (2005) Calibration and evaluation of seven fracture models. Int J Mech Sci 47(4–5):719–743. https://doi.org/10.1016/j.ijmecsci.2005.03.003CrossRef

26.

Wang K (2016) Calibration of the Johnson-Cook failure parameters as the chip separation criterion in the modelling of the orthogonal metal cutting process. http://hdl.handle.net/11375/19091

27.

Wu CJ, Li BZ, Liang SY (2016) A critical energy model for brittle–ductile transition in grinding considering wheel speed and chip thickness effects. P I Mech Eng 230(8):1372–1380. https://doi.org/10.1177/0954405416654194CrossRef

28.

Holmquist TJ, Johnson GR (2005) Characterization and evaluation of silicon carbide for high-velocity impact. J Appl Phys 97(9) https://doi.org/10.1063/1.1881798

29.

Dai JH, Su HH, Zhou WB, Yu TF, Ding WF, Zhang QL, Zheng YH (2018) Finite element implementation of the tension-shear coupled fracture criterion for numerical simulations of brittle-ductile transition in silicon carbide ceramic grinding. Int J Mech Sci 146:211–220. https://doi.org/10.1016/j.ijmecsci.2018.07.043CrossRef

30.

Johnson GR, Holmquist TJ (1994) An improved computational constitutive model for brittle materials. Am J Phys 309(1):981–984. https://doi.org/10.1063/1.46199CrossRef

31.

Zhou JK, Lu MM, Lin JQ, Zhou XQ, Du YS, Wang C, Diao YL (2022) Investigation and simulation based on mesoscopic model of SiCp/Al composites during precision machining: deformation mechanism and surface quality. Int J Adv Manuf Tech 119:2173–2186. https://doi.org/10.1007/s00170-021-08407-2CrossRef

32.

Pen HM, Guo JH, Cao ZZ, Wang XC, Wang ZG (2018) Finite element simulation of the micromachining of nanosized-silicon-carbide-particle reinforced composite materials based on the cohesive zone model. Nanotechnol Precis Eng 1(4):242–247. https://doi.org/10.1016/j.npe.2018.12.003CrossRef

33.

Title: Study on the formation mechanism of surface defects in the processing of large particle SiCp/Al composites
Authors: Zhigao Chen
Bo Wang
Duo Li
Ziteng Li
Mingjun Chen
Publication date: 23-02-2024
Publisher: Springer London
Published in: The International Journal of Advanced Manufacturing Technology / Issue 7-8/2024
Print ISSN: 0268-3768
Electronic ISSN: 1433-3015
DOI: https://doi.org/10.1007/s00170-024-13287-3

Springer Professional

Abstract

Please log in to get access to your license.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Springer Professional "Technik"

Other articles of this Issue 7-8/2024

Comparative investigation and optimization of cutting tools performance during milling machining of titanium alloy (Ti6Al4V) using response surface methodology

Cold formability of friction stir processed 5754-H111 and 6082-T6 aluminum alloys: an experimental and numerical study

Distribution analysis of deterministic clamping and positioning error for machining of ring-shaped workpieces considering alignment uncertainty

A new redundancy strategy for enabling graceful degradation in resilient robotic flexible assembly cells

Modeling and experimental analysis of ultrasonic vibration drilling force prediction model for tiny small holes in high body fraction aluminum-based silicon carbide composites

Comparative life cycle assessment of aluminium and CFRP composites: the case of aerospace manufacturing

Premium Partners