Al/SiCp composite material is rapidly advanced due to its applications to weapon, military, aeronautics and astronautics. In some cases, fields of research are stagnating for its difficulty in material processing. In this study, we are particularly concerned about the cutting mechanism of Al/SiCp through modeling and simulations on wear rate of the tools. These simulations of tool wear rate and cutting mechanism of Al/SiCp are proved by cutting tests on Al/SiCp with nanocemented carbide tool WC-7Co and common cemented carbide tool YG8. A detailed investigation suggests that the cutting instinct of Al/SiCp is of interrupted cutting process. And the grain loss, less tipping and blade fracture during tool wear results from high frequency intermittent shock by SiC grain. The wear behavior on the tool flank is mainly of grain loss. However, the wear behavior of the rake face is not only of grain loss, but also abrasive wear of WC grain by SiC grain. It is conclusively demonstrated that the model of tool wear rate is sufficient for revolution characterization of tool wear rate on grain size, volume fraction of reinforcement, and also significantly important to prove the interrupted cutting process mechanism of Al/SiCp.

The relationship of the friction coefficient and the MTC were discussed, and the MTC and its effects on surface roughness were a theoretical analysised and experimental verification by AFM (atomic force microscope). The results show that the theoretical MTC tends to be minimal value then before the adhering effect to reach remarkable. Appropriate adjustments cutting parameters, the cutting process can always micro-cutting phase to reach the steady-thin chip, and no plowing phenomenon. So the surface residues highly were reduced and higher surface quality was achieved.