Cutting Simulations and Experiments of Milled SIC Particle-Reinforced Aluminum Matrix Composites

When SiC particles are added into aluminum, property of aluminum is greatly improved during a reinforcing phase to produce particle reinforced aluminum composites. However, cutting tools wear out quickly and it is difficult to meet machining accuracy and surface quality requirements due to the rough surface produced by the reinforcement process. This paper presents a simulation model of SiC particle-reinforced aluminum matrix composites is established considering particles, cohesive elements, and material matrix. Stress distribution and surface roughness are analyzed for SiC/Al matrix composites based on the cutting process. Experiments are performed to test the degree of surface roughness using different cutting parameters. The relationship of cutting depth, cutting velocity, and feed rate per tooth to surface roughness degree is obtained for SiC/Al matrix composites. The optimization of cutting process is performed based on simulation. The results lay a foundation on the optimization of machining processes for metal matrix composites.