1. Engineering Training Center, Dalian University of Technology, Dalian 116023, China 2. Marine Engineering College, Dalian Maritime University, Dalian 116026, China
SiC particle reinforced aluminum matrix (SiCp/Al) composites contain irregular silicon carbide particles, causing a large number of non ideal cross-sections in the material, which makes it difficult to remove the surface of the material effectively. Simulation analysis and experimental verification of surface removal of SiCp/Al composite with variable cutting depth were carried out, in order to reveal the mechanism of material removal. Results show that the interface failure has an important impact on surface formation and there are removal processes such as aluminum alloy matrix tearing, interface separating; silicon carbide particles exposing, crack propagation, breaking and falling off, pressing into aluminum alloy matrix, debris sliding against the material surface, etc. The large area of the silicon carbide particles crushing and falling off, causes pit defect and the material is subjected to secondary cutting under the tool push, so that the surface of the aluminum matrix forms non-continuous cracks. In SiCp/Al composites, the actual cutting depth is less than the nominal cutting depth due to the existence of aluminum alloy matrix. Research in this paper can provide some references for the study of removal mechanism and processing of SiCp/Al composites.
Hong-zhe ZHANG,Xu ZHANG,Xiao-chun ZHU,Yong-jie BAO. Surface removal mechanism study of SiCp/Al composites based on single-point cutting test. Journal of ZheJiang University (Engineering Science), 2022, 56(2): 388-397.
Tab.1Johnson-Cook constitutive model and failure parameters of 2A12 Al alloy[14-15]
材料 参数
E/ GPa
μ
τ/ (10?6 K?1)
ρ/ (103 kg·m?3)
$\lambda $/ (W·m?1·K?1)
c/ (J·kg?1·K?1)
2A12 铝合金
71.7
0.33
26.6
2.77
175
921
碳化硅
420.0
0.14
4.9
3.13
81
427
Tab.2Physical and mechanical property parameters of 2A12 Al alloy and SiC[15-16]
Fig.1Mesh generation and boundary conditions of micro scale finite element model for SiCp/Al composites
Fig.2Experimental device and method of single-point cutting test in accordance with actual grinding parameters
h/μm
r/mm
v/（m?s?1）
Δt/s
vf/（mm?min?1）
n/(r?min?1)
20
162
5.26
0.10~0.15
100
310
Tab.3Parameters of single-point cutting test in accordance with actual range of grinding parameters
Fig.3Surface morphology of 2A12 aluminum alloy, 65% SiCp/2A12 Al composite and SiC ceramic after pretreatment
Fig.4Simulation of aluminum alloy matrix removal process in SiCp/Al composites
Fig.5Simulation of formation process of pit defects in SiCp/Al composites caused by SiC particle breakage
Fig.6Simulation of deformation process of SiC particles removal in SiCp/Al composites
Fig.7Simulation of secondary cutting process of SiC particles in SiCp/Al composites
Fig.8Longitudinal section outline curves of three materials and micro morphology of SiCp/Al composites with different cutting depth values
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