Simulation Experiment Research On Grinding Of High Volume Fraction SiCp/Al Composites

The medium and high volume fraction Si Cp/Al(silicon carbide particle reinforced aluminum matrix)composite has excellent properties such as high specific strength,high specific modulus,wear resistance and low thermal expansion coefficient.At the same time,it has the characteristics of mature and diverse preparation technologies and low cost.Now it has been widely used in advanced optics,aerospace,electronic packaging and other fields.However,brittle and hard reinforced Si C particles and soft and tough Al matrix have significant differences in physical and mechanical properties,As a result,the processing quality of Si Cp/Al composite with medium and high volume fraction cannot be guaranteed,making it a typical difficult to process material.Grinding is an important and advantageous processing method for machining medium and high volume fraction Si Cp/Al composites.Its advantages lie in the high strength and self sharpening of grinding wheel grains.At present,the grinding quality of high volume fraction Si Cp/Al composites still needs to be improved,the material removal mechanism needs to be further deepened,and the processing parameters need to be further optimized.In the grinding process of high volume fraction Si Cp/Al composites,the interaction between grinding wheel abrasive particles and workpiece(reinforced Si C and matrix Al)is very complex,and the grinding process parameters have an important influence on the machining quality of workpiece.In order to reveal the grinding removal mechanism of high volume fraction Si Cp/Al composites,and effectively master the basic influence of grinding process parameters on the machining quality before the physical experiment,this thesis uses the finite element simulation technology to carry out the grinding simulation experiment research of high volume fraction Si Cp/Al composites,overcoming and making up the shortcomings of traditional experiments.The finite element simulation experiment can reflect the contact state of the grinding wheel grain workpiece(reinforced Si C and matrix Al),the interaction between the reinforced Si C and matrix Al,the material removal process and the evolution of the sub surface material state in real time and intuitively at the micro scale.In addition,the finite element simulation experiment can make up for the problems such as the long cycle and high cost of the traditional experiment,and the difficulty in preparing the machined surface/sub surface interview samples required for SEM observation.Through finite element simulation experiments,this thesis reveals the material removal process in the grinding process of high volume fraction Si Cp/Al composites,analyzes the influence of grinding process parameters on the surface roughness and sub surface damage depth,and carries out the grinding quality prediction and grinding process parameter optimization of high volume fraction Si Cp/Al composites through the data driven optimization design system DADOS.Finally,the simulation experiment is verified by the physical test.The specific research contents are as follows:(1)Parametric modeling of grinding wheel and high volume fraction Si Cp/Al composites.Analyze the size,shape and arrangement of the abrasive particles on the surface of the grinding wheel,use Python program to carry out the parametric modeling of the grinding wheel in Abaqus software,and realize the visualization of the parametric modeling of the grinding wheel through the GUI plug-in.Analyze the microscopic characteristics of Si C particles,use Matlab software and Solidworks software to carry out Si C particle group modeling,and use Abaqus software to build a high volume fraction Si Cp/Al composite material model according to the Si C particle group model.(2)Simulation experiment research on grinding surface quality of high volume fraction Si Cp/Al composites.Through single factor test,the single influence rule of removal process of high volume fraction Si Cp/Al composite and grinding process parameters on grinding surface quality is analyzed.The significance of the influence of grinding process parameters on the machined surface quality is analyzed through50 groups of full factor tests,and training data is provided for the subsequent simulation of surface quality prediction and optimization of grinding process parameters for high volume fraction Si Cp/Al composite grinding.50 groups of multi factor tests are designed by the optimal Latin hypercube sampling method(OLHS).(3)Simulation experiment on grinding subsurface damage of high volume fraction Si Cp/Al composites.Through single factor simulation experiment,the formation process of grinding subsurface damage of high volume fraction Si Cp/Al composite was analyzed,and the influence of grinding process parameters on the depth of subsurface damage was explored.(4)Data driven surface quality prediction and grinding process parameter optimization for grinding simulation of high volume fraction Si Cp/Al composites.Using the data driven optimization design system DADOS and the above 50 groups of multi factor tests as training data,the data driven surface quality prediction and grinding process parameter optimization of high volume fraction Si Cp/Al composite grinding simulation were carried out.(5)Physical experiment verification.Through the grinding experiment of high volume fraction Si Cp/Al composite materials,the grinding surface morphology and subsurface damage of high volume fraction Si Cp/Al composite materials are analyzed,and the validity of the grinding simulation experiment analysis of high volume fraction Si Cp/Al composite materials is verified,as well as the reliability of the surface quality prediction of the grinding simulation of high volume fraction Si Cp/Al composite materials based on data driven.