不同体积分数SiCp/Al复合材料单颗磨粒划切仿真与试验研究

SiCp/Al复合材料由性能差异巨大的碳化硅颗粒与铝合金基体组成，切削过程复杂，影响加工质量因素多，材料仿真建模困难。本文提出了虑及颗粒随机分布特性、形状、粒径、体积分数等因素的SiCp/Al复合材料参数化建模方法，研究了不同体积分数SiCp/Al复合材料的去除过程、切削力、表面形貌及损伤等，并进行了试验验证。仿真分析与试验结果表明，参数化建模效果较好。SiCp/Al复合材料具有表面损伤严重、切削力大、基体涂覆掩盖表面缺陷、实际切削深度小等特点，不能单纯以表面粗糙度评价SiCp/Al复合材料的加工质量。粒径大、体积分数高的SiCp/Al切削力、比磨削能更低，表面质量更差，实际切削深度更小，铝合金涂覆现象更严重且覆盖层易脱落。SiC粒径对表面损伤、切削力、比磨削能有重要影响。本文可为SiCp/Al复合材料表面去除特点研究与工程应用提供一定的借鉴。

Simulation and experimental study on single point cutting SiCp/Al composites with different volume fraction

SiCp/Al composites are composed of SiC particles and aluminum alloy matrix with great performance differences. The cutting process is complex, and there are many factors affecting the processing quality, and the material simulation modeling is difficult. In this paper, a parametric modeling method of SiCp/Al composites is proposed considering the random distribution of particles, particle size, volume fraction and other factors. The removal process, cutting force, surface morphology and damage of SiCp/Al composites with different volume fraction are studied and verified by experiments. The simulation analysis and experimental results show that the parametric modeling is effective. SiCp/Al composites are characterized by severe surface damage, high cutting force, surface defects covered by substrate coating, and small actual cutting depth. The processing quality of SiCp/Al composites can not be evaluated by surface roughness alone. SiCp/Al with large particle size and high volume fraction has lower cutting force, lower specific grinding energy, worse surface quality, smaller actual cutting depth, more serious coating phenomenon and easier coating falling off. SiC particle size has an important influence on surface damage, cutting force and specific grinding energy. This paper can provide some references for the surface removal characteristics research and engineering application of SiCp/Al composite.