Finite element and experimental studies of the formation mechanism of edge defects during machining of SiCp/Al composites

In this paper, a multi-particle microfinite element model with a random particle distribution in SiCp/Al composites was developed using ABAQUS software. The formation mechanism of edge defects near the exit of orthogonal cutting was analyzed, and the effects of cutting parameters on the sizes of edg...

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Bibliographic Details
Published in:International journal of machine tools & manufacture 2014-09, Vol.84, p.9-16
Main Authors: Zhou, L., Wang, Y., Ma, Z.Y., Yu, X.L.
Format: Article
Language:English
Subjects:
Aluminum
Cutting parameters
Cutting speed
Defects
Edge defects
Finite element
Formation mechanism
Formations
Mathematical models
Orthogonal cutting experiment
Particulate composites
SiCp/Al composites
Silicon carbide
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Summary:In this paper, a multi-particle microfinite element model with a random particle distribution in SiCp/Al composites was developed using ABAQUS software. The formation mechanism of edge defects near the exit of orthogonal cutting was analyzed, and the effects of cutting parameters on the sizes of edge defects were investigated. The results indicate that both the brittle fracture of SiC particles and the plastic flow of Al matrix occur in the process of the edge defects formation. Additionally, the cutting speed has little effect on the sizes of edge defects but the cutting depth has a significant effect on the height and length of edge defects. The numerical results were also compared to the orthogonal cutting experimental data and found to be in reasonable agreement. •A multi-particle microfinite element model of SiCp/Al composites is developed to predicted formation mechanism of edge defects.•The impact and cutting depth on the sizes of edge defects is the main factor.•Predicted edge defects agree well with experimental results.
ISSN:0890-6955
1879-2170
DOI:10.1016/j.ijmachtools.2014.03.003