目的 阐明增强相颗粒的断裂演化机制与材料去除行为规律,对提升SiCP/Al金属基复合材料加工表面成形质量、精准优选切削工艺参数及构建高效加工工艺体系具有重要的理论价值与工程指导意义。方法 本文依托Abaqus有限元软件构建SiCP/Al复合材料细观切削仿真模型,结合切削过程颗粒应力分布与基体塑性变形特征,对比分析激光超声振动辅助切削、激光辅助切削、超声振动辅助切削及常规切削4种工艺,明确不同工况下SiC颗粒断裂形式、裂纹扩展规律与材料去除机理的差异。通过数值模拟表征不同切削工艺的表层微观损伤特征,结合实际切削试验,利用表面形貌与粗糙度实测数据验证仿真模型的准确性,进一步分析切削速度、切削深度、进给量等工艺参数对不同加工方式下表面粗糙度的影响规律。结果 仿真与试验结果表明,激光超声复合切削可协同发挥热软化与动态冲击作用,实现SiC颗粒可控渐进脆断与界面协同剥离,材料去除过程稳定有序,表面粗糙度最大降幅可达24.86%,可有效抑制颗粒剥落、表面划痕、基体撕裂等加工损伤,在提升工件表面完整性方面效果最优。此外,工艺参数会显著影响复合加工的作用效果,直接改变表面质量改善程度。故而依据实际加工需求合理选配加工参数,是充分发挥该复合切削工艺优势,实现SiCP/Al复合材料高质量切削加工的重要前提。结论 激光超声振动辅助切削在改善工件加工表面形貌、降低表面粗糙度、抑制表层加工损伤等方面具备显著技术优势,可有效提升复合材料切削加工表面完整性。而加工工艺参数的合理匹配与优选,是充分释放该加工方式性能潜力、发挥其表面提质增效作用的关键。
Abstract
SiCp/Al metal matrix composites are fabricated with aluminum alloy as the matrix and silicon carbide ceramic particles as the reinforcing phase. The two constituent materials complement each other and endow the composite with outstanding comprehensive performance. The fabricated material features low density and remarkable lightweight advantages, excellent thermal conductivity, and tunable coefficient of thermal expansion by adjusting the SiC particle content, which enables favorable thermal turning with semiconductor chips and ceramic substrates. It also boasts strong shock resistance and superior dimensional stability under temperature fluctuations. Meanwhile, the composite possesses high stiffness, favorable wear resistance, and anisotropic mechanical properties. It retains the electrical conductivity of aluminum, supports welding and electroplating, and exhibits satisfactory corrosion resistance and electromagnetic shielding capacity, making it widely applicable to electronic packaging and aerospace precision components. Nevertheless, the uniformly dispersed ultra-hard SiC particles in the aluminum matrix lead to large turning resistance and severe tool wear, which greatly restrict its forming process. Conventional turning suffers from high processing difficulty and excessive manufacturing cost. To achieve precision machining of SiCp/Al composites, a laser-ultrasonic vibration hybrid turning method has been proposed by researchers. Elucidating the fracture evolution mechanism of reinforcing particles and the corresponding material removal laws is of vital theoretical value and engineering guiding significance for optimizing the turned surface forming quality of SiCp/Al composites, accurately selecting turning parameters, and establishing an efficient manufacturing framework.
In this paper, a mesoscopic turning simulation model of SiCp/Al composites is established based on Abaqus finite element software. Combined with particle stress distribution and matrix plastic deformation characteristics during turning, four turning processes, namely laser-ultrasonic vibration assisted turning, laser assisted turning, ultrasonic vibration assisted turning and conventional turning, are compared and analyzed. The distinctions in SiC particle fracture modes, crack propagation paths and material removal mechanisms under different thermomechanical coupling conditions are clarified. Numerical simulations are utilized to characterize superficial micro-damage induced by different turning processes. Corresponding turning experiments are carried out. A Zygo interferometer is adopted to accurately measure surface roughness under the four turning schemes, and a scanning electron microscopy (SEM) is used to capture surface micro-morphologies. The measured topography and roughness data are applied to verify the accuracy of the simulation model. Furthermore, the influence laws of cutting speed, depth of cut and feed rate on surface roughness for each turning method are systematically investigated.
Simulation and experimental results demonstrate that the hybrid laser-ultrasonic turning realizes synergistic effects of thermal softening of the aluminum matrix, thermal embrittlement of SiC particles and high-frequency dynamic impact. This coupling effect triggers controllable and progressive brittle fracture of SiC particles and maintains a stable and ordered material removal process. Compared with conventional turning, the optimized hybrid turning reduces surface roughness Ra by up to 24.86%. This technology can effectively suppress typical turning defects including particle spalling, deep surface scratches and matrix tearing, delivering optimal performance in improving the surface integrity of workpieces. In addition, turning parameters significantly modulate the functional performance of the hybrid energy field and directly determine the improvement range of turned surface quality. Therefore, reasonable matching and selection of processing parameters according to practical manufacturing demands serve as an essential prerequisite to fully exploit the advantages of this hybrid turning technology and realize high-quality turning of SiCp/Al composites
关键词
SiCp/Al复合材料 /
激光超声振动辅助切削 /
颗粒断裂和去除行为 /
表面质量 /
Abaqus仿真
Key words
SiCP/Al composites /
laser-ultrasonic vibration assisted turning /
particle fracture removal behavior /
surface quality /
Abaqus simulation
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基金
国家自然科学基金区域创新发展联合基金重点支持项目（U24A20126）; 国家自然科学基金青年科学基金项目（52405452）; 吉林省自然科学基金（20260102046JC）
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