Simulation Study on the Mechanism of Particle Failure and Surface Defect Formation in Machining of SiCp / Al Composites

In order to reveal the mechanism of SiC particle failure and the effect of particle failure on the microscopic morphological defects of SiCp / Al composites during cutting, a finite element model of single-particle SiCp / Al composites was established, and the process of particle failure and surface defect formation under different tool-particle relative positions and cutting speeds were investigated. With the stress field analyzed, particle failure process and tool-particle contact force, it is found that the relative tool-particle position has a significant effect on SiC particle failure, stress field and tool-particle contact force, that there are various forms of particle failure which affects the formation of surface defects on machined surfaces, and that the cutting speed has little influence on the evolution of particle failure and tool-particle contact force. The simulation results show good agreement with the surface morphology obtained from experiments. The various types of particle failure are explained by differences in stress fields and tool-particle contact forces at different tool-particle relative positions. © 2022 Cailiao Daobaoshe/ Materials Review. All rights reserved.