Modeling and evaluation in grinding of SiCp/Al composites with single diamond grain

Yin, Guoqiang; Gong, Yadong; Li, Youwei; Song, Jiaxin; Zhou, Yunguang

doi:10.1016/j.ijmecsci.2019.105137

Cited by 48 publications

(8 citation statements)

References 25 publications

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“…Since the maximum rotational speed at which the UAG machining system can ensure a smooth experiment is 25 krpm, parameters within the range of 0–21 krpm were selected as parameter variables for v s . The variables v w and a p were selected as references [ 29 ]. The reliability and stability of machining will be affected if these values are set too large.…”

Section: Methodsmentioning

confidence: 99%

Experimental Studies of the Machinability of SiCp/Al with Different Volume Fractions under Ultrasonic-Assisted Grinding

Hu,

Zhu,

Fan

2024

Materials

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High-volume fraction silicon carbide particle-reinforced aluminum (SiCp/Al) has a promising application for its high specific strength, wear resistance, and thermal conductivity. However, SiCp/Al components with a high-volume fraction are prone to poor surface quality and defects such as fractures, cracks, and micro-pits. It has been reported that ultrasonic-assisted grinding machining (UAG) helps to improve the quality of SiCp/Al machined surfaces. However, the differences between SiCp/Al with different volume fractions obtained by UAG machining are not clear. Therefore, a comparative study of surface roughness, morphology, and cutting force was carried out by UAG machining on SiCp/Al samples with volume fractions of 45% and 60%. Compared to the 45% volume fraction SiCp/Al, the 60% volume fraction SiCp/Al has a higher cutting force and roughness under the same machining parameters. In addition, experiments have shown that cutting forces and surface roughness can be reduced by increasing the tool speed or decreasing the feed rate. UAG machining with an ultrasonic amplitude within 4 μm can also reduce cutting forces and surface roughness. However, more than 6 μm ultrasonic amplitude may lead to an increase in roughness. This study contributes to reasonable parameter settings in ultrasonically-assisted grinding of SiCp/Al with different volume fractions.

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Section: Methodsmentioning

confidence: 99%

Experimental Studies of the Machinability of SiCp/Al with Different Volume Fractions under Ultrasonic-Assisted Grinding

Hu,

Zhu,

Fan

2024

Materials

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“…This finding further highlights the challenges associated with processing SiCp/Al. The grinding process of SiCp/Al involves four stages of material removal: plastic removal of the aluminum matrix, crack initiation of SiC particles, crack propagation of SiC particles, and brittle fracture of SiC particles [ 123 ]. The removal of SiC particles primarily occurs due to interface failure between the reinforcement and matrix, resulting from microcracks on the interface and numerous fractured or crushed SiC particles on the surface.…”

Section: Grinding Machining Of Sicp/almentioning

confidence: 99%

A Review on Machining SiCp/Al Composite Materials

Chen,

Ding,

Zhang

et al. 2024

Micromachines

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SiCp/Al composite materials are widely used in various industries such as the aerospace and the electronics industries, primarily due to their excellent material properties. However, their machinability is significantly weakened due to their unique characteristics. Consequently, efficient and precise machining technology for SiCp/Al composite materials has become a crucial research area. By conducting a comprehensive analysis of the relevant research literature from both domestic and international sources, this study examines the processing mechanism, as well as the turning, milling, drilling, grinding, special machining, and hybrid machining characteristics, of SiCp/Al composite materials. Moreover, it summarizes the latest research progress in composite material processing while identifying the existing problems and shortcomings in this area. The aim of this review is to enhance the machinability of SiCp/Al composite materials and promote high-quality and efficient processing methods.

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“…Also, the ultrasonic vibration maintains a constant frequency f and amplitude A. (5)The debonding of SiC particles is ignored, considering the size ratio of diamond grits to SiC particles, which means the particle fracture is the main form of particle damage.…”

Section: Development Of Force Modelmentioning

confidence: 99%

“…These composites contain a high-volume fraction of SiC particles with high hardness and wear resistance. In addition, due to the plasticity of the aluminum alloy matrix, SiCp/Al often adheres to the tool surface during machining and deteriorates the cutting environment [5]. Therefore, SiCp/Al composites are recognized in the industry as typically difficult-to-machining hard and brittle composite materials.…”

Section: Introductionmentioning

confidence: 99%

Modeling for Ultrasonic Vibration-assisted Helical Grinding of SiC particle-reinforced Al-MMCs

Li¹,

Yuan

Gao³

et al. 2023

Preprint

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Silicon carbide (SiC) particle-reinforced aluminum matrix (SiCp/Al) composites have continuously increased applications in abundant industries due to their superior mechanical properties. However, such composites have issues achieving desired machinability and quality standard due to the presence of SiC particles which is the main hindrance to their applications. In this paper, the methodology of ultrasonic vibration-assisted helical grinding (UVHG) of SiCp/Al composites has been applied to achieve to desired quality and efficiency for such composites. Then a mechanical cutting force model was developed to predict grinding forces. The grinding force was separated into friction force, plastic deformation force, and fracture force on account of the material removal mechanism. The undeformed chip thickness and cross-sectional area were calculated for the grinding force of a single diamond abrasive grit and then extended to the whole tool. By considering the acoustic softening effect of reduction of deformation stress caused by ultrasonic vibration, the acoustic softening coefficient was first proposed in the model to correct the impact of the ultrasonic vibration for properties of SiCp/Al composites. The experimental machining (UVHG) was carried out considering the different groups of experiments. The experimental results found agreed with the predicted values of cutting forces. The prediction deviation of the model was 7.06%, which could provide further guidance for the grinding process optimization of SiCp/Al composites. The novel cutting force predicted model and proposed machining methodology could be applied to machining SiCp/Al composites at the industry level and further research work.

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Modeling and evaluation in grinding of SiCp/Al composites with single diamond grain

Cited by 48 publications

References 25 publications

Experimental Studies of the Machinability of SiCp/Al with Different Volume Fractions under Ultrasonic-Assisted Grinding

Experimental Studies of the Machinability of SiCp/Al with Different Volume Fractions under Ultrasonic-Assisted Grinding

A Review on Machining SiCp/Al Composite Materials

Modeling for Ultrasonic Vibration-assisted Helical Grinding of SiC particle-reinforced Al-MMCs

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