Research on Micro-Cutting Mechanism of CoCrFeNiAlX High-Entropy Alloy Particle Reinforced 7A09 Aluminum Matrix Composites

This study investigates the micro-cutting mechanism of a 7A09 aluminum matrix composite reinforced with CoCrFeNiAlX (referred to as AlX) high-entropy alloy particles, chosen for their superior wetting properties with aluminum. Using simulation analysis, the research explores how high-entropy alloy particles with varying aluminum content influence the micro-cutting behavior of the aluminum-based composite. The results indicate that cutting force is minimized when the cutting path is above the particle and maximized when below, with a difference of approximately 201 N. Cutting force increases with cutting speed, but the rate of change varies significantly across speeds, with a maximum increase of 67%. The highest cutting temperatures, at 301 °C and 304 °C, are observed when cutting depth and speed are maximized, respectively, with temperature more strongly influenced by cutting speed, leading to a temperature variation of up to 148 °C across different speeds. For composites with different aluminum contents, cutting temperatures follow the order Al1 > Al0.6 > Al0. When the cutting path passes above the particle, thinner chips undergo multiple fractures due to tensile stress; as the path shifts downward, chip breakage frequency increases with cutting depth. At a constant cutting depth, low-speed cutting produces discontinuous chips, while higher speeds yield more continuous chips, achieving the most complete chip formation at 1500 m/min. The surface smoothness, qualitatively reflected by nodal displacement, ranks as follows: path b > path d > path c > path a > path e. This research provides valuable data to enhance machining performance for high-entropy alloy particle-reinforced aluminum matrix composites.