Study on Milling Mechanism and Surface Quality of High Volume Fraction SiCp/Al2024 Composites

2021 ◽  
Author(s):  
Po Jin ◽  
Qi Gao ◽  
Quanzhao Wang ◽  
Xiaofei Jing
Keyword(s):  
Surface Quality ◽  
Volume Fraction ◽  
High Volume ◽  
High Volume Fraction

scholarly journals Face Grinding Surface Quality of High Volume Fraction SiCp/Al Composite Materials

2021 ◽  
Vol 34 (1) ◽  
Author(s):  
Xu Zhao ◽  
Yadong Gong ◽  
Guiqiang Liang ◽  
Ming Cai ◽  
Bing Han
Keyword(s):  
Friction Coefficient ◽  
Surface Morphology ◽  
Surface Quality ◽  
Volume Fraction ◽  
High Volume ◽  
Spindle Speed ◽  
High Volume Fraction ◽  
Machining Parameters ◽  
Al Composite

AbstractThe existing research on SiCp/Al composite machining mainly focuses on the machining parameters or surface morphology. However, the surface quality of SiCp/Al composites with a high volume fraction has not been extensively studied. In this study, 32 SiCp/Al specimens with a high volume fraction were prepared and their machining parameters measured. The surface quality of the specimens was then tested and the effect of the grinding parameters on the surface quality was analyzed. The grinding quality of the composite specimens was comprehensively analyzed taking the grinding force, friction coefficient, and roughness parameters as the evaluation standards. The best grinding parameters were obtained by analyzing the surface morphology. The results show that, a higher spindle speed should be chosen to obtain a better surface quality. The final surface quality is related to the friction coefficient, surface roughness, and fragmentation degree as well as the quantity and distribution of the defects. Lower feeding amount, lower grinding depth and appropriately higher spindle speed should be chosen to obtain better surface quality. Lower feeding amount, higher grinding depth and spindle speed should be chosen to balance grind efficiently and surface quality. This study proposes a systematic evaluation method, which can be used to guide the machining of SiCp/Al composites with a high volume fraction.

scholarly journals Study on Meso-scale Grinding Surface Roughness and Sub-surface Quality of High Volume Fraction SiCp/Al2024 composites

2021 ◽  
Author(s):  
Guangyan Guo ◽  
Qi Gao ◽  
Quanzhao Wang ◽  
Yuanhe Hu
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Volume Fraction ◽  
Aluminum Matrix ◽  
High Volume ◽  
High Volume Fraction ◽  
Aluminum Matrix Composites ◽  
Sic Particles ◽  
Meso Scale

Abstract In order to improve the surface grinding quality of high volume fraction aluminum matrix composites, the cutting tool models with different rake angles are established, the grinding process is simulated, and the material removal mechanism and the broken state of SiC particles are obtained. Through single factor experiment, the 60% volume fraction SiCp/Al2024 composites are ground by diamond grinding rod with 3mm diameter, the surface roughness (Ra) is measured, and the surface and sub-surface quality of SiCp/Al2024 composites with meso-scale grinding is investigated. Meanwhile, the influence mechanism of grinding depth (ap) on surface quality is put forward, and the influence of different grinding depth on the fragmentation of SiC particles in sub-surface layer is discussed, which verifies the correctness of grinding simulation. The relevant research and theoretical model are of great significance to the study of grinding properties of composite materials.

Study on Removal Mechanism and Surface Quality of High Volume Fraction SiCp/Al Composites Based on Meso-scale

2021 ◽  
Author(s):  
Po Jin ◽  
Qi Gao ◽  
Quanzhao Wang ◽  
Wenbo Li
Keyword(s):  
Particle Size ◽  
Surface Quality ◽  
Feed Rate ◽  
Volume Fraction ◽  
High Volume ◽  
Milling Process ◽  
Subsurface Damage ◽  
High Volume Fraction ◽  
Removal Mechanism

Abstract The milling process of SiCp/Al composites with high volume fraction and large particle size has been studied in this paper. The stress and strain distribution of SiC reinforced particles and the removal mechanism of the material are analysed. The effects of milling depth and feed per tooth on surface quality were analysed. The effect of feed per tooth on the thickness of subsurface damage layer is revealed. The results show that in the end milling process of high volume fraction SiCp/Al composites, the blade diameter is larger relative to the particle size, which leads to the main removal forms of particle size: extrusion crushing and rolling crushing. The surface defects of the machined workpiece mainly include cavity, crack and delamination caused by extrusion of aluminum matrix. The surface quality of the machined workpiece can be improved by increasing the milling depth appropriately. The increase of the feed rate of each tooth will lead to the increase of the surface defect of the machined workpiece and the deterioration of the surface quality. When the feed rate per tooth increases from 4 to 8 μm, the thickness of subsurface damage increases from 47.7 to 60.5 μm. It is found that the ratio between the minimum cutting thickness of SiCp/Al composites and the radius of the cutting edge should be less than or equal to 4%.

Experimental Study on Surface Quality at Different Milling Speed of High Volume Fraction SiCp/Al Thin Walled Test-Piece

2014 ◽  
Vol 800-801 ◽  
pp. 15-19 ◽  
Author(s):  
Ke Ru Jiao ◽  
Shu Tao Huang ◽  
Li Fu Xu
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Surface Quality ◽  
Test Piece ◽  
Volume Fraction ◽  
High Volume ◽  
Middle Part ◽  
High Volume Fraction ◽  
Inferior Surface ◽  
Thin Walled

In order to investigate the influence of milling velocity on surface roughness of the cutting entrance, middle part and cutting exit, high milling experiment for the thin walled test-piece of high volume fraction SiCp/Al composites was preformed with PCD tool. The results indicate that when milling at lower speed 60m/min, the SiCp/Al test-piece is apt to vibrate. As well as, the surface roughness machined test-piece in cutting exit increases obviously and its Ra value reaches 1.721μm, which leads to the inferior surface quality. In conclusion, the surface roughness, either at cutting entrance, middle or at cutting exit, all is a decline trend with the milling speed increasing. Moreover, Ra value of the cutting entrance is the biggest, followed by the middle, and the cutting exit is the smallest.

Mechanical Properties of MWCNT Modified Syntactic Foams with High Volume Fraction of Glass Microspheres

2014 ◽  
Vol 1000 ◽  
pp. 122-125 ◽  
Author(s):  
Martina Drdlová ◽  
Michal Frank ◽  
Jaroslav Buchar ◽  
Josef Krátký
Keyword(s):  
Mechanical Properties ◽  
Carbon Nanotubes ◽  
Volume Fraction ◽  
Syntactic Foam ◽  
High Volume ◽  
High Volume Fraction ◽  
Syntactic Foams ◽  
Glass Microspheres ◽  
Multi Wall Carbon Nanotubes

The effect of multi-wall carbon nanotubes content on physico-mechanical properties of glass microspheres-epoxy resin syntactic foam was evaluated experimentally. Syntactic foam with high volume fraction of microspheres (70 vol%) was prepared and modified by 1 to 5 vol% of multi-wall carbon nanotubes. The compressive, flexural and impact strength tests were conducted, the load-displacement curves were captured. The quality of dispersion of nanoparticles was evaluated in relation to the mixing procedure using scanning electron microscope observation.

Synthesis of high-temperature thermally expandable microcapsules and their effects on foaming quality and surface quality of foamed ABS materials

e-Polymers ◽  
2020 ◽  
Vol 20 (1) ◽  
pp. 519-527
Author(s):  
Wei Gong ◽  
Xianglin Pei ◽  
Xiaogang Yin ◽  
Daming Ban ◽  
Hai Fu ◽  
...  
Keyword(s):  
High Temperature ◽  
Surface Quality ◽  
Volume Fraction ◽  
Crosslinking Agent ◽  
Acrylonitrile Butadiene Styrene ◽  
Foaming Agent ◽  
Blowing Agent ◽  
Good Surface ◽  
Butadiene Styrene

AbstractIn this paper, acrylonitrile and hydroxypropyl acrylate are used as the binary polymerization monomers, and isooctane is used as the foaming agent to prepare high-temperature thermally expandable microcapsules. Analysis of the effect of blowing agent and crosslinking agent on the expansion properties of high-temperature thermally expandable microcapsules, the effects of foaming agent azodicarbonamide (ADCA) and micro-expansion capsule on the surface quality and foaming quality of foamed acrylonitrile–butadiene–styrene (ABS) products were investigated. The foamed product prepared by the high-temperature microcapsule has a good surface quality, the gloss is 52.3, the cell is not easily deformed, and the volume fraction is 4%; the foamed ABS/ADCA material has poor cell uniformity, the cell is easily deformed, the volume fraction is 6.5%, the surface quality is poor, and the gloss is only 8.7.

scholarly journals Study on the High-Speed Milling Performance of High-Volume Fraction SiCp/Al Composites

Materials ◽  
2021 ◽  
Vol 14 (15) ◽  
pp. 4143
Author(s):  
Youzheng Cui ◽  
Shenrou Gao ◽  
Fengjuan Wang ◽  
Qingming Hu ◽  
Cheng Xu ◽  
...  
Keyword(s):  
High Speed ◽  
Large Scale ◽  
Volume Fraction ◽  
Simulation Analysis ◽  
Cutting Temperature ◽  
High Volume ◽  
Cutting Parameters ◽  
High Volume Fraction ◽  
High Wear Resistance ◽  
Element Analysis

Compared with other materials, high-volume fraction aluminum-based silicon carbide composites (hereinafter referred to as SiCp/Al) have many advantages, including high strength, small change in the expansion coefficient due to temperature, high wear resistance, high corrosion resistance, high fatigue resistance, low density, good dimensional stability, and thermal conductivity. SiCp/Al composites have been widely used in aerospace, ordnance, transportation service, precision instruments, and in many other fields. In this study, the ABAQUS/explicit large-scale finite element analysis platform was used to simulate the milling process of SiCp/Al composites. By changing the parameters of the tool angle, milling depth, and milling speed, the influence of these parameters on the cutting force, cutting temperature, cutting stress, and cutting chips was studied. Optimization of the parameters was based on the above change rules to obtain the best processing combination of parameters. Then, the causes of surface machining defects, such as deep pits, shallow pits, and bulges, were simulated and discussed. Finally, the best cutting parameters obtained through simulation analysis was the tool rake angle γ0 = 5°, tool clearance angle α0 = 5°, corner radius r = 0.4 mm, milling depth ap = 50 mm, and milling speed vc= 300 m/min. The optimal combination of milling parameters provides a theoretical basis for subsequent cutting.

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