Chip Formation Mechanisms and the Process Model during Ultra-precision Turning of SiCp/Al Composite

doi:10.3969/j.issn.1000-1093.2015.05.022

Abstract

Abstract: Single crystal diamond and polycrystalline diamond tools are selected for ultra-precision turning of SiC particulate reinforced aluminum matrix composites (SiC_p/2024Al and SiC_p/ZL101A). The appearance and the metallurgical microstructure of chip are observed in order to investigate the formation mechanisms of chip using micromechanics and metal cutting theory analytical methods. The chip formation process models are also established. The results show that a saw-toothed chip with semi-periodic thickness is formed. It is pointed that the dynamic behavior of microcracks and the periodic variation of shear angle are the two main mechanisms for this type of chip. A great number of microcracks and microvoids are produced on this kind of material during machining due to the inherent defects and, non-uniformity of the materials and the presence of the reinforcement particles. The periodic variation of shear angle is determined by the workpiece microstructure and the mechanical properties and the periodic slip-stick phenomenon. Volume fraction of reinforcement, cutting speed, feed rate and tool edge radius are the main factors that affect the chip formation.

Key words: manufaturing technology and equipment, particulate reinforced aluminum matrix composite, ultra-precision turning, chip formation mechanism, chip formation process model, dynamic behavior of microcrack, shear angle

CLC Number:

TG506.7

GE Ying-fei， XU Jiu-hua, YANG Hui. Chip Formation Mechanisms and the Process Model during Ultra-precision Turning of SiC_p/Al Composite[J]. Acta Armamentarii, 2015, 36(5): 911-920.

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Chip Formation Mechanisms and the Process Model during Ultra-precision Turning of SiC_p/Al Composite

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