Numerical study on machining of Al/SiC composite materials

Abstract Metal matrix composites (MMCs) comprising aluminum (Al) matrices reinforced with silicon carbide (SiC) particles have garnered significant attention in recent years due to their outstanding specific strength, stiffness, corrosion resistance, and thermal conductivity. However, to achieve the desired geometry and shape of such MMC workpiece, a cutting process is still necessary, which involves a complex phenomenon of mechanical interactions that can result in surface defects and reduced tool life. This study aims to numerically investigate the cutting process of Al/SiC MMC workpieces in a manner that closely resembles reality by developing a finite element model directly from a metallographic image of a composite with a 30% volume fraction of 10 μm SiC grit. The research focuses on the effects of cutting depth, cutter rake, and the interaction between the cutting tool and the SiC particles. The results demonstrate that, depending on the contact point with the SiC particle, there is a variation in the cutting force generated when the cutter tip encounters the SiC particle. This causes the particle to break, rotate, roll over the matrix, and embed deeper into the matrix. Furthermore, based on the analysis of variance applied to the cutting force, the cutting depth exhibits a significant influence, while the cutter rake shows no significant effect on the cutting force.