Study of Machining Process of SiCp/Al Particle Reinforced Metal Matrix Composite Using Finite Element Analysis and Experimental Verification

Laghari, Rashid Ali; Li, Jianguang; Wu, Yi

doi:10.3390/ma13235524

Cited by 27 publications

(7 citation statements)

References 48 publications

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“…One is caused by the cutting edge making direct contact with the particle, while the other is caused by the tool and particle interacting indirectly with the matrix. Laghari et al [ 12 ] quantitatively examined the impact of interfacial characteristics on the strengthening effect of SiCp/Al composites by adding an interfacial layer to a single particle cutting simulation model. It is demonstrated that the stiff interface model had a stronger enhancing impact than the flexible interface model as the thickness of the interface increased.…”

Section: Introductionmentioning

confidence: 99%

Simulation and Experimental Analysis of Surface Defects in Turning of TiCp/TC4 Composites

et al. 2022

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Processing TiCp/TC4 composites has always been difficult due to the mismatch between the mechanical and thermal properties of the matrix and the reinforced particles, which results in a variety of machined surface defects. To expose the mechanism of defect generated on the cutting surface of TiCp/TC4 composites and improve their cutting surface quality, a 3D finite element orthogonal turning simulation model of TiCp/TC4 composites is developed. The failure at the matrix-particle interface and the fracture and removal mechanism of the reinforcing phase particles are analyzed from a microscopic perspective using a single particle cutting simulation model. In addition, a three-dimensional cutting simulation model with randomly dispersed TiC particles and a volume fraction of 5% is developed, and various forms of cutting surface defects of TiCp/TC4 composites are examined. To verify the validity of the finite element simulation model, TiCp/TC4 composites with a volume fraction of 5% are selected for turning tests. For various cutting tools and particle relative positions, the simulation and test results show that the removal of particles takes the following forms: debonding, crushing, brittle fracture, and slight fracture at the top, leading to a shallow cavity, microcracks, residual TiC particles embedded in the cavity, and surface defects with severe plastic deformation of the matrix surrounding the cavity on the machined surface.

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Section: Introductionmentioning

confidence: 99%

Simulation and Experimental Analysis of Surface Defects in Turning of TiCp/TC4 Composites

et al. 2022

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“…Therefore, the researches on cutting of difficult-to-machine materials are particularly important. Since there is more cutting heat during the cutting process, the temperature in the cutting zone is higher, which leads to cutting to a certain extent [30,31].…”

Section: Introductionmentioning

confidence: 99%

Modeling and optimization of cutting forces and effect of turning parameters on SiCp/Al 45% vs SiCp/Al 50% metal matrix composites: a comparative study

Laghari

2021

SN Appl. Sci.

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In this study, the proposed experimental and second-order model for the cutting forces were developed through several parameters, including cutting speed, feed rate, depth of cut, and two varying content of SiCp. Cutting force model was developed and optimized through RSM and compared for two different percentages of components SiCp/Al 45% and SiCp/Al 50%. ANOVA is used for Quantitative evaluation, the main effects plot along with the evaluation using different graphs and plots including residual analysis, contour plots, and desirability functions for cutting forces optimization. It provides the finding for choosing proper parameters for the machining process. The plots show that during increment with depth of cut in proportion with feed rate are able to cause increments in cutting forces. Higher cutting speed shows a positive response in both the weight percentage of SiCp by reducing the cutting force because of higher cutting speed increases. A very fractional increasing trend of cutting force was observed with increasing SiCp weight percentages. Both of the methods such as experiment and model-predicted results of SiCp/Al MMC materials were thoroughly evaluated for analyzing cutting forces of SiCp/Al 45%, and SiCp/Al 50%, as well as calculated the error percentages also found in an acceptable range with minimal error percentages. Article Highlights This study focuses on the effect of cutting parameters as well as different percentage of SiC particles on the cutting forces, while comparing the results of both SiC particles such as SiCp/Al 45%, and SiCp/Al 50% the result shows that there isn’t fractional amount of impact on the cutting force with nominal increasing percentages of SiC particles. Cutting speed in machining process of SiCp/Al shows positive response in reducing the cutting forces, however, increasing amount of depth of cut followed by increasing feed rate creates fluctuations in cutting force and thus increases the cutting force in the cutting process. The developed RSM mathematical model which is based on the box Behnken design show excellent competence for predicting and suggesting the machining parameters for both SiCp/Al 45%, and SiCp/Al 50% and the RSM mathematical model is feasible for optimization of the machining process with good agreement to experimental values.

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“…Al-Si alloys are widely used as lightweight materials in aerospace, automotive parts, and other fields due to their excellent casting properties, high strength, and strong corrosion resistance [ 1 , 2 ]. SiCp has the characteristics of isotropy, low expansion coefficient, and high strength, which are ideal reinforcing materials for preparing metal matrix composites [ 3 , 4 ]. SiCp/Al-Si composites combine the advantages of SiC and Al-Si alloys in strength, expansion, and wear resistance [ 5 , 6 ].…”

Section: Introductionmentioning

confidence: 99%

Effect of CeO2 Content on Microstructure and Properties of SiCp/Al-Si Composites Prepared by Powder Metallurgy

et al. 2021

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The effect of CeO2 content on the microstructure and properties of SiCp/Al-Si composites prepared by powder metallurgy was studied, and the mechanism of CeO2 in composites was deeply analyzed. The results show that the addition of the appropriate amount of CeO2 can refine the Si particles and improve the tensile properties of the SiCp/Al-Si composites. As the CeO2 content increases from 0 to 0.4 vol%, the particle size of the Si phase shows a tendency to decrease first and then increase, while the tensile strength, yield strength, and elongation of the composites show a trend of first increasing and then decreasing. When the CeO2 content is 0.2 vol%, the refining effect of CeO2 and the tensile properties of composites are the best. The fracture mode of SiCp/Al-Si composites with a rare earth addition is a mixed fracture. There are three main mechanisms for CeO2 in SiCp/Al-Si composites. One is when CeO2 serves as the nucleation substrate of Si phase to refine Si particles. The second is when CeO2 reacts with the alloying elements in the aluminum matrix to form a new phase, CeCu2Si2, which can not only play a role of dispersion strengthening, but also improve the bonding strength between Al matrix and Si particles. The third is the pinning effect of CeO2 and CeCu2Si2 particles on grain boundaries or phase boundaries to refine aluminum grains.

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Study of Machining Process of SiCp/Al Particle Reinforced Metal Matrix Composite Using Finite Element Analysis and Experimental Verification

Cited by 27 publications

References 48 publications

Simulation and Experimental Analysis of Surface Defects in Turning of TiCp/TC4 Composites

Simulation and Experimental Analysis of Surface Defects in Turning of TiCp/TC4 Composites

Modeling and optimization of cutting forces and effect of turning parameters on SiCp/Al 45% vs SiCp/Al 50% metal matrix composites: a comparative study

Effect of CeO2 Content on Microstructure and Properties of SiCp/Al-Si Composites Prepared by Powder Metallurgy

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