Simulation study on chip formation mechanism in grinding particle reinforced Cu-matrix composites

Based on the coupling method of finite element method and smoothed particle hydrodynamics method, the process of single abrasive grain cutting particles reinforced Cu-matrix composites with small volume fraction of particle phase is simulated, and the chip formation mechanism of particle reinforced Cu-matrix composites was analyzed. It can be concluded that the plastic removal of the Cu-matrix is still the main removal form of the composite, but the existence of the reinforced particle phase affects the cutting deformation behavior and the chip morphology. During the cutting process, the interfaces between part of reinforced particles and the Cu-matrix are broken, and resulting in the particles falling off into chips, but most of the particles will form continuous mixed chips with copper alloy, with the plastic deformation of the Cu-matrix. The extrusion of abrasive particles leads to pile-up of dislocation producing in Cu-matrix around the reinforced particle, which interferes with the continuous plastic deformation of Cu-matrix, thus affects the cutting force and cutting temperature of the abrasive grain. The simulation results show that with the increase of cutting speed, the cutting force decreases, but the cutting temperature increases. As the cutting depth increases, the cutting force and cutting temperature increase. The increase of reinforced particle content will lead to the increase of cutting force and cutting temperature.