| FANG Yu-xin,WANG You-qiang,ZHANG Ping,WANG Xue-zhao.High-speed Cutting Removal Mechanism and Surface Quality of SiCp/Al Composites[J],51(10):293-300 |
| High-speed Cutting Removal Mechanism and Surface Quality of SiCp/Al Composites |
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| DOI：10.16490/j.cnki.issn.1001-3660.2022.10.031 |
| KeyWord:SiCp/Al composites high-speed machining surface quality working hardened |
| Author | Institution |
| FANG Yu-xin |
Qingdao University of Technology, School of Mechanical and Automotive Engineering, Shandong Qingdao ,China ;Key Lab of Industrial Fluid Energy Conservation and Pollution Control, Ministry of Education Qingdao, Shandong Qingdao , China |
| WANG You-qiang |
Qingdao University of Technology, School of Mechanical and Automotive Engineering, Shandong Qingdao ,China ;Key Lab of Industrial Fluid Energy Conservation and Pollution Control, Ministry of Education Qingdao, Shandong Qingdao , China |
| ZHANG Ping |
East China University of Science and Technology, School of Mechanical and Power of Engineering, Shanghai , China |
| WANG Xue-zhao |
Qingdao University of Technology, School of Mechanical and Automotive Engineering, Shandong Qingdao ,China ;Key Lab of Industrial Fluid Energy Conservation and Pollution Control, Ministry of Education Qingdao, Shandong Qingdao , China |
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| Abstract: |
| SiCp/2024Al composites, which are particle-reinforced aluminum matrix composites, have the advantages of high specific strength and specific module, high hardness, excellent wear and corrosion resistance, etc., and have a broad application prospect in the aerospace field, but they also have issues such as serious tool wear and poor surface quality in their machining due to the hard particle-reinforced phase, making them difficult to machine, whereas high-speed machining, as an advanced manufacturing technology, is a highly advantageous technical means for the machining of difficult-to-machine materials in addition to high machining efficiency and precision. Therefore, high-speed orthogonal milling experiments were conducted in this paper for 45% volume fraction SiCp/2024Al composites to compare their machinability over a wide range of cutting speeds and to analyze their chip formation mechanism and machined surface quality under high-speed machining.High-speed orthogonal milling experiments on flake SiCp/2024Al composites were conducted by controlling the cutting speed in the speed range of 300-1 000 m/min. In the experiments, the cutting edge of the insert was made parallel to the spindle direction, and the width of the cutting edge was ensured to be larger than the thickness of the workpiece. The chip morphology, cutting force, cutting energy consumption, machined surface morphology and machining hardening were collected and monitored to investigate the material removal mechanism and machining surface quality changes under high-speed machining in order to analyze the high-speed machinability of SiCp/2024Al composites. The experimental results show that the chip formation process of composites at lower cutting speeds consists of shear deformation and SiC particle fragmentation in the primary deformation zone, and the chip morphology is serrated. In the cutting speed range of 300-800 m/min, the chip continuity of composites decreased as the speed increased, and the composites underwent a ductile-to-brittle transition at 1 000 m/min, and the chips gradually appeared to be fragmented. The cutting force in the cutting speed range of 300-1 000 m/min decreased significantly as cutting speed increased, and the main cutting force decreased from about 320 N at 300 m/min to about 180 N at 1 000 m/min, and the cutting energy consumption also decreases significantly with the increase of cutting speed, the cutting energy consumption decreases from 1.07 GJ/m3 at 300 m/min to 0.62 GJ/m3 at 1 000 m/min. The failed SiC particles damaged the machined surface, while the high-speed machining improved the surface quality. With a cutting speed of 300-1 000 m/min, the surface roughness decreases from 0.68 μm to 0.47 μm, and the machining hardening depth also decreases with the increase of cutting speed. High cutting speed corresponds to higher strain rate, summarize the above findings, the dynamic mechanical behavior of the composites changes under high-speed machining, and the material undergoes a ductile-to-brittle transition, which affects the degree of deformation of the removed layer material and the machined surface, resulting in a decrease in chip continuity, increased brittleness, and the cutting force and cutting energy consumption decrease. The deformation of the machined surface decreases, and the surface quality improves, so high-speed machining under certain conditions can help improve the machinability of SiCp/2024Al composites. |
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