International Journal of Extreme Manufacturing, Volume. 2, Issue 4, 45103(2020)

Microstructure-based three-dimensional characterization of chip formation and surface generation in the machining of particulate-reinforced metal matrix composites

Qi Wu1...2 and Liangchi Zhang12,* |Show fewer author(s)
Author Affiliations
  • 1School of Mechanical and Manufacturing Engineering, The University of New South Wales, NSW 2052, Australia
  • 2Department of Mechanics and Aerospace Engineering, Southern University of Science and Technology, Shenzhen 518055, Guangdong, People’s Republic of China
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    Particulate-reinforced metal matrix composites (PRMMCs) are difficult to machine due to the inclusion of hard, brittle reinforcing particles. Existing experimental investigations rarely reveal the complex material removal mechanisms (MRMs) involved in the machining of PRMMCs. This paper develops a three-dimensional (3D) microstructure-based model for investigating the MRM and surface integrity of machined PRMMCs. To accurately mimic the actual microstructure of a PRMMC, polyhedrons were randomly distributed inside the matrix to represent irregular SiC particles. Particle fracture and matrix deformation and failure were taken into account. For the model’s capability comparison, a two-dimensional (2D) analysis was also conducted. Relevant cutting experiments showed that the established 3D model accurately predicted the material removal, chip morphology, machined surface finish, and cutting forces. It was found that the matrix-particle-tool interactions led to particle fractures, mainly in the primary shear and secondary deformation zones along the cutting path and beneath the machined surface. Particle fracture and dilodegment greatly influences the quality of a machined surface. It was also found that although a 2D model can reflect certain material removal features, its ability to predict microstructural variation is limited.

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    Qi Wu, Liangchi Zhang. Microstructure-based three-dimensional characterization of chip formation and surface generation in the machining of particulate-reinforced metal matrix composites[J]. International Journal of Extreme Manufacturing, 2020, 2(4): 45103

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    Paper Information

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    Received: May. 16, 2020

    Accepted: --

    Published Online: Apr. 16, 2021

    The Author Email: Zhang Liangchi (zhanglc@sustech.edu.cn)

    DOI:10.1088/2631-7990/abab4b

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