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

In this paper, Abaqus software was used to construct a SiCp/Al2024 composite cutting simulation model with a multi-particle random distribution model, and the particle removal mechanism and surface defect evolution under mesoscopic size were analyzed. In addition, the influence of spindle speed on particle removal and surface defect formation was studied, and the best cutting parameter combination was explored. The results show that in the milling of high volume fraction SiCp/Al2024 composites, because the cutting edge radius of the tool is much larger than the particle size, the main form of particle removal is crushing. The surface defects of the workpiece mainly include pits, cracks, scratches and sliding layers. Increasing the cutting speed will increase the surface defects of the workpiece and the surface quality will deteriorate. The feed rate has the greatest influence on the surface roughness, followed by the spindle speed, and the milling depth has the least influence. The best combination of surface roughness is 14000 r/min spindle speed, 0.072 m/min feed rate and 45 μm milling depth. At this time, the surface roughness of the workpiece is 0.578 μm.