Research On The Cutting Simulation Of SiCp/Al Composite And Experimental Verification

SiCp/Al composite material has an essential applied value in aerospace,automobile and electronics because of its outstanding material properties,such as Light weight,high strength and stiffness,small thermal expansion coefficient,good dimensional stability and performance of thermal conductivity,w ear resistance,corrosion resistance,etc.In the meantime,because of its high hardness,the presence of SiC particles cause serious tool wear and more defects on the machined surface,making Si Cp/Al material become a kind of hard processing material,which hider the wider use of this material.Therefore,it is necessary to have a further research on sic particle reinforced aluminum matrix composites processing technology.This thesis studied the Si Cp/Al composite material cutting process based on the finite element simulation technology as the main research method,combining with the experimental method,to provide reference significance on the development of Si Cp/Al composite materials processing technology and the optimization of cutting parameters.Firstly,a two-dimensional orthogonal cutting simulation model of Si Cp/Al composite was established.The geometry and material constitutive model of the particle,the matrix and the interface layer have been modeled.In view of the distribution of the particles in the matrix,this thesis proposed respectively a two-dimensional particle random distribution algorithm and wrote the corresponding Python scripts on the secondary development of ABAQUS to simulate the different size,different volume fraction of particles randomly distributed in the matrix.The cohesion model has been adopted to describe the constitutive relation of interface layer.On the basis of cohesive unit,this thesis compiled cohesion model using custom material subroutine VUMAT.Secondly,the cutting state of Si C reinforced particles was analyzed.Three different location of Si C particle relative to the cutting tool path was simulated to analyze the cutting state such as the particle removal.The interface layer was introduced to the case that the particle was on the cutting path to study the influence to the stress and strain transfer.Through the post-processing of simulation result,the influence of interface property on the composite reinforcement effect was studied quantificationally.Finally,the cutting process of Si Cp/Al composite material was simulated.This thesis designed a single factor finite element analysis solution and studied the influence on the machined surface morphology,chip morphology,stress distribution and cutting force of many factors,such as particle position,particle size distribution,particle volume fraction,particle size and the cutting speed,cutting thickness.The single factor orthogonal cutting experiment was designed the influence of cutting speed and feed on the cutting force.The cutting force results of the experiment and the simulation were compared through the deviation analysis,which verified the simulation model.