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Volume 2 Issue 4
Sep.  2020
Article Contents

Wu Q, Zhang L C. 2020. Microstructure-based three-dimensional characterization of chip formation and surface generation in the machining of particulate-reinforced metal matrix composites. Int. J. Extrem. Manuf. 2, 045103.
Citation: Wu Q, Zhang L C. 2020. Microstructure-based three-dimensional characterization of chip formation and surface generation in the machining of particulate-reinforced metal matrix composites. Int. J. Extrem. Manuf. 2, 045103.

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


doi: 10.1088/2631-7990/abab4b
More Information
  • Publish Date: 2020-09-02
  • 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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    沈阳化工大学材料科学与工程学院 沈阳 110142

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

doi: 10.1088/2631-7990/abab4b
  • 1 School of Mechanical and Manufacturing Engineering, The University of New South Wales, NSW 2052, Australia
  • 2 Department of Mechanics and Aerospace Engineering, Southern University of Science and Technology, Shenzhen 518055, Guangdong, People’s Republic of China

Abstract: 

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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