Micro-milling mechanism and surface roughness of high volume fraction SiCp/Al composites

In this paper, a finite element simulation model of diamond tool milling SiCp/Al composites was established. The cutting stress, stress distribution and material removal mechanism of the SiC-reinforced material were studied. At the same time, the correctness of the finite element simulation was verified by a micro-milling experiment. The results show that the main particle removal methods include pulling out, crushing and pressing in and that the particle removal methods are different when the tool is cutting at different positions. With increasing cutting speed, the surface defects of the material are reduced and the surface quality is improved. The main surface defects in the milling process are voids, microcracks, scratches and pits. Through the optimization of cutting parameters, it is found that the milling depth has the greatest effect on the surface roughness, the spindle speed has the second greatest effect, and the feed rate has the least effect. The surface roughness of the machined workpiece is 0.238 mu m when the process parameters have been optimized.

Automated summary

This paper established a finite element simulation model and conducted a micro-milling experiment to study the cutting stress, stress distribution, and material removal mechanism of diamond tool milling SiCp/Al composites. The results showed that cutting speed affects surface defects and quality, while optimizing cutting parameters can improve surface roughness.