Force Prediction and Material Removal Mechanism Analysis of Milling SiCp/2009Al

In recent years, medium- and low-volume fraction silicon carbide particle-reinforced aluminum matrix composites (SiCp/Al) have increasingly become a key material in the aerospace industry. Force prediction and material removal mechanism analysis of milling SiCp/Al are necessary to improve the surfac...

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Bibliographic Details
Published in:Micromachines (Basel) 2022-10, Vol.13 (10), p.1687
Main Authors: Wang, Rong, Zhao, Man, Mao, Jian, Liang, Steven
Format: Article
Language:English
Subjects:
Aerospace industry
Aluminum base alloys
Aluminum matrix composites
Carbides
Composite materials
Cutting parameters
Empirical analysis
Experiments
Feed rate
Machining
Milling (machining)
milling force
milling parameters
Particle size
Particulate composites
Plastic deformation
Process parameters
Raw materials
Regression analysis
removal mechanism
SiCp/Al composites
Silicon carbide
Silicon compounds
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Summary:In recent years, medium- and low-volume fraction silicon carbide particle-reinforced aluminum matrix composites (SiCp/Al) have increasingly become a key material in the aerospace industry. Force prediction and material removal mechanism analysis of milling SiCp/Al are necessary to improve the surface integrity of products. An orthogonal experiment of SiCp/2009Al with a volume fraction of 20% was carried out, and the effect of the milling parameters on milling force was studied with the input parameters of milling speed, feed rate, and milling depth. Thereby, the empirical force model of milling SiCp/2009Al is established by fitting the experiential data based on the multiple linear regression analysis methods. Moreover, the effects of the milling parameters on the force were analyzed. Finally, the material removal mechanism of milling SiCp/Al is analyzed based on dislocation theory. The analyzed results reveal that the removal mechanism of the SiCp/Al composites includes plastic deformation of the aluminum matrix, cutting of particles, fragmentation, and deboning. Based on dislocation theory and maximum undeformed thickness theory, the effect of cutting parameters on the form of material removal was analyzed, which serves as a guide for selecting appropriate machining parameters to obtain improved machining quality of SiCp/Al composites.
ISSN:2072-666X
2072-666X
DOI:10.3390/mi13101687