Article
Engineering, Mechanical
Lisheng Zuo, Wendeng Shao, Xingquan Zhang, Dunwen Zuo
Summary: This study investigates the issue of tool wear during friction stir welding of SiCp/Al composites. A new method for calculating tool wear based on hydrodynamic pressure is proposed and a tool pin wear prediction model is established and verified through experiments. The results show that the AlCrN coating can extend the tool life to a certain extent, but the wear rate increases significantly after the coating is worn away. The main mechanisms of tool wear in the friction stir welding of SiCp/Al composites are identified as the micro ploughing and micro cutting of SiC particles.
Article
Engineering, Mechanical
Ye Chen, Qi Gao, Quanzhao Wang, Xunyu Yin
Summary: Silicon carbide particles reinforced aluminum matrix composites are widely used in national defense and related high-end technology fields due to their excellent mechanical properties. This study conducted high-velocity milling experiments on 20% volume SiCp/Al2009 composites using a polycrystalline diamond (PCD) tool, established a three-dimensional milling model for SiCp/Al composites, comprehensively analyzed the influence of milling parameters on surface quality, described the cutting mechanism, and revealed the wear forms and mechanism of PCD tools during milling. The results showed that cutting depth, spindle speed, and feed rate influenced the machined surface quality, with cutting depth having the largest effect. The optimal milling parameters were found to be a spindle speed of 17,000 r/min, a feed rate of 8 mm/min, and a cutting depth of 0.04 mm, resulting in the smallest surface roughness value of Ra=0.056 μm. Surface morphology included pits, cracks, and burrs, while subsurface defects included particle breakage, peeling, and matrix cracks, and the tool wear forms included chipping, flaking, and bond wear.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART C-JOURNAL OF MECHANICAL ENGINEERING SCIENCE
(2023)
Article
Automation & Control Systems
Po Jin, Qi Gao, Quanzhao Wang, Wenbo Li
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.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Chemistry, Physical
Youzheng Cui, Shenrou Gao, Fengjuan Wang, Qingming Hu, Cheng Xu, Fengxia Xu
Summary: This study simulated the milling process of SiCp/Al composites using the ABAQUS/explicit platform and optimized the cutting parameters, providing a theoretical basis for subsequent cutting.
Article
Automation & Control Systems
Ke Zhang, Qi Gao, Quanzhao Wang, Ye Chen, Tianyang Cui, Xunyu Yin
Summary: This study investigates the effects of milling on the fracture and deformation of SiCp/Al composites, as well as the influence of cutting speed on particle damage and surface quality. The optimal cutting conditions are determined through orthogonal experiments, and the causes of surface defects are explained through analysis of subsurface morphology.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
Maojun Li, Zhuoling Wang, Wei Li, Xujing Yang
Summary: In this study, a two-phase finite element model was developed to investigate particle removal mechanisms and surface integrity during milling of SiCp/Al composites. The results showed that compressive residual stress mainly appeared on the machined surface, while tensile residual stress distributed at deeper depth. Different relative positions between tool and particle induced specific particle removal modes and surface defects.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE
(2022)
Article
Automation & Control Systems
Rashid Ali Laghari, Ning He, Muhammad Jamil, Munish Kumar Gupta
Summary: The use of MQL and CO2 in wet machining improves the machinability of SiCp/Al materials, reducing cutting forces, improving surface quality, and prolonging tool life.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Materials Science, Ceramics
Xu Wang, Valentin L. Popov, Zhanjiang Yu, Yiquan Li, Jinkai Xu, Qiang Li, Huadong Yu
Summary: The cutting performance of textured polycrystalline diamond tools on SiCp/Al composites was studied and it was found that texture parameters play a significant role in machining. Textured tools reduce cutting force and tool wear, improve surface quality, and change the chip flow direction. The cutting mechanism of textured tools was elucidated through numerical simulation.
CERAMICS INTERNATIONAL
(2022)
Article
Engineering, Industrial
Shijin Lu, Zengqiang Li, Junjie Zhang, Chunyu Zhang, Guo Li, Haijun Zhang, Tao Sun
Summary: This study investigates the coupled influence of rake angle of cutting tool and tool-particle position on the ultra-precision diamond cutting of SiCp/Al through finite element simulations and corresponding experiments. The results reveal different failure modes of SiC particles and their correlations with cutting force, chip profile, and machined surface integrity. The findings emphasize the significant role of the rake angle of the cutting tool in altering the stress state in the tool-particle contact region and its strong coupled effect with the tool-particle position on the diamond cutting of SiCp/Al.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2022)
Article
Automation & Control Systems
Emine Sap, Usame Ali Usca, Munish Kumar Gupta, Mustafa Kuntoglu
Summary: The study investigated the effects of different machining parameters on Cu/Mo-SiCp composites during turning, finding that the particle additive ratio was the most important parameter affecting surface roughness, tool wear, and cutting temperature. It was also observed that chip types and wear types changed with increasing reinforcement rates.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Automation & Control Systems
Lei Gao, Chang Liu, Zhaoxin Hou, Cheng Li, Renfeng Shen, Tao Yang
Summary: This paper studied the effect of particle volume fractions on the wear characteristics of multi-coated cutting tools when turning SiCp/Al composites. Results showed that the increase of PVFs accelerated the removal of coating and the peeling of the adhesive layer. The wear characteristics on the flank face were characterized by adhesive wear, abrasive wear, and coating shedding, which remained consistent whether in different PVFs or at different wear stages.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Automation & Control Systems
Qiulin Niu, Lu Jing, Changping Li, Zhen Yu, Shujian Li, Pengnan Li, Xinyi Qiu, TaeJo Ko, Wenhui Yue
Summary: By optimizing the tool nose radius, the edge defects of SiCp/Al composites can be improved. Experimental results showed that with an increase in tool nose radius, the chips became shorter and wider, and cutting force also increased.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Electrical & Electronic
Huiping Zhang, Liqiang Qu, Chenglong Ding
Summary: In this study, single-factor and central combination high-speed milling tests were conducted on SiCp/Al composites using a PCD tool under cryogenic liquid nitrogen cooling conditions to investigate the surface roughness, surface morphology, surface microhardness, and surface residual stress. The results showed that the surface roughness increased gradually with an increase in feed or milling depth, and the interaction between the two factors aggravated this phenomenon. The surface microhardness and surface residual stress initially increased and then decreased as the milling speed varied from 200 to 360 m/min, indicating that a speed above 240 m/min is recommended for milling under cryogenic liquid nitrogen cooling conditions. Moreover, the degree of surface microhardness significantly improved with an increase in milling depth and feed, and the residual compressive stress tended to convert to residual tensile stress. The simulation results also revealed that the interference effect of SiC particles on internal residual stress transfer increased with an increase in milling depth and feed per tooth, indicating that high milling depths and high feed per tooth should not be used simultaneously.
Article
Automation & Control Systems
Tao Chen, Jiaqiang Liu, Chunhui Li, Jianyi Zhang, Guangyue Wang, Maoyue Li
Summary: This study conducted a comparative experimental study on inclined angle milling and spiral milling of CFRP and analyzed the milling axial force, tool wear, quality of hole entrance and exit, and micro-morphology of the hole wall under the two milling methods. The results showed that inclined angle milling exhibited a relatively smaller and smoother axial force compared to spiral milling. The wear pattern of the milling tool was also different between the two methods.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Automation & Control Systems
Kai-jiang Li, Yan-ling Liao, Yu-mei Zhou, Feng-lin Zhang, Jiang-wen Liu, Shi-xiong Wu, Hong-qun Tang, Xiao-yi Pan
Summary: This paper investigates the dry grinding characteristics of SiCp/Al composites with different micro-textures on monolayer brazed diamond grinding wheels. The results show that the micro-textures on diamond grits induce cleavages and form more micro-cutting edges during the grinding of SiCp/Al. The wheel with micro-grooves and micro-holes exhibits the lowest grinding force, grinding temperature, and surface integrity. It also produces smaller grinding chips and reduces the fracture, crushing, and pull-out of SiC particles on the ground surface of SiCp/Al composites compared to other wheels.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)