High-volume fraction silicon particle-reinforced aluminium matrix composites(Si/Al)are increasingly applied in aerospace,radar communications,and large-scale integrated circuits because of their superior thermal condu...High-volume fraction silicon particle-reinforced aluminium matrix composites(Si/Al)are increasingly applied in aerospace,radar communications,and large-scale integrated circuits because of their superior thermal conductivity,wear resistance,and low thermal expansion coefficient.However,the abrasive and adhesive wear caused by the hard silicon reinforcement and the ductile aluminium matrix leads to significant tool wear,decreased machining efficiency,and compromised surface quality.This study combines theoretical analysis and cutting experiments to investigate polycrystalline diamond(PCD)tool wear during milling of 70 vol%Si/Al composite.A key contribution of this work is the development of a tool wear model that incorporates reinforcement particle characteristics,treating them as ellipsoidal structures,which enhances the accuracy of predicting abrasive and adhesive wear mechanisms.The model is based on abrasive and adhesive wear mechanisms,and can analyze the interaction between silicon particles,aluminium matrix,and tool components,thus providing deeper insights into PCD tool wear processes.Experimental validation of the model shows a good agreement with the results,with a mean deviation of approximately 10%.The findings on the tool wear mechanism reveal that,as tool wear progresses,the proportion of abrasive wear increases from 40%in the running-in stage to 75%in the rapid wear stage,while adhesive wear decreases.The optimal machining parameters of 120 m·min^(–1) cutting speed(v_(c))and 0.04 mm·z^(–1) feed rate(f_(z)),result in tool life of 33 min and surface roughness(S_(a))of 2.2μm.The study uncovers the variation patterns of abrasive and adhesive wear during the tool wear process,and the proposed model offers a robust framework for predicting tool wear during the machining of high-volume fraction Si/Al composites.The research findings also offer key insights for optimizing tool selection and machining parameters,advancing both the theoretical understanding and practical application of PCD tool wear.展开更多
Chipping, adhesive wear, abrasive wear and crater wear are prevalent for both the polycrystalline diamond （PCD） and the carbide tools during high speed turning of TiCp/TiBw hybrid reinforced Ti-6Al-4V （TC4） matrix...Chipping, adhesive wear, abrasive wear and crater wear are prevalent for both the polycrystalline diamond （PCD） and the carbide tools during high speed turning of TiCp/TiBw hybrid reinforced Ti-6Al-4V （TC4） matrix composite （TMCs）. The combined effects of abrasive wear and diffusion wear caused the big crater on PCD and carbide tool rake face. Compared to the PCD, bigger size of crater was found on the carbide tool due to much higher cutting temperature and the violent chemical reaction between the Ti element in the workpiece and the WC in the tool. However, the marks of the abrasive wear looked much slighter or even could not be observed on the carbide tool especially when low levels of cutting parameters were used, which attributes to much lower hardness and smaller size of WC combined with more significant chemical degradation of carbide. When cutting TC4 using PCD tool, notch wear was the most significant wear pattern which was not found when cutting the TMCs. However, chipping, adhesive wear and crater wear were much milder when compared to the cutting of titanium matrix composite. Due to the absence of abrasive wear when cutting TC4, the generated titanium carbide on the PCD protected the tool from fast wear, which caused that the tool life for TC4 was 6-10 times longer than that for TMCs.展开更多
基金supported by the National Natural Science Foundation of China(Grant No.52075255)the Jiangsu Provincial Science and Technology Plan(Grant No.BZ2023005).
文摘High-volume fraction silicon particle-reinforced aluminium matrix composites(Si/Al)are increasingly applied in aerospace,radar communications,and large-scale integrated circuits because of their superior thermal conductivity,wear resistance,and low thermal expansion coefficient.However,the abrasive and adhesive wear caused by the hard silicon reinforcement and the ductile aluminium matrix leads to significant tool wear,decreased machining efficiency,and compromised surface quality.This study combines theoretical analysis and cutting experiments to investigate polycrystalline diamond(PCD)tool wear during milling of 70 vol%Si/Al composite.A key contribution of this work is the development of a tool wear model that incorporates reinforcement particle characteristics,treating them as ellipsoidal structures,which enhances the accuracy of predicting abrasive and adhesive wear mechanisms.The model is based on abrasive and adhesive wear mechanisms,and can analyze the interaction between silicon particles,aluminium matrix,and tool components,thus providing deeper insights into PCD tool wear processes.Experimental validation of the model shows a good agreement with the results,with a mean deviation of approximately 10%.The findings on the tool wear mechanism reveal that,as tool wear progresses,the proportion of abrasive wear increases from 40%in the running-in stage to 75%in the rapid wear stage,while adhesive wear decreases.The optimal machining parameters of 120 m·min^(–1) cutting speed(v_(c))and 0.04 mm·z^(–1) feed rate(f_(z)),result in tool life of 33 min and surface roughness(S_(a))of 2.2μm.The study uncovers the variation patterns of abrasive and adhesive wear during the tool wear process,and the proposed model offers a robust framework for predicting tool wear during the machining of high-volume fraction Si/Al composites.The research findings also offer key insights for optimizing tool selection and machining parameters,advancing both the theoretical understanding and practical application of PCD tool wear.
基金supported by the National Natural Science Foundation of China (No.51275227)Nanjing Science and Technology Development Plan (201306024) of Chinathe Qinglan Project of Jiangsu Province (2014) of China
文摘Chipping, adhesive wear, abrasive wear and crater wear are prevalent for both the polycrystalline diamond （PCD） and the carbide tools during high speed turning of TiCp/TiBw hybrid reinforced Ti-6Al-4V （TC4） matrix composite （TMCs）. The combined effects of abrasive wear and diffusion wear caused the big crater on PCD and carbide tool rake face. Compared to the PCD, bigger size of crater was found on the carbide tool due to much higher cutting temperature and the violent chemical reaction between the Ti element in the workpiece and the WC in the tool. However, the marks of the abrasive wear looked much slighter or even could not be observed on the carbide tool especially when low levels of cutting parameters were used, which attributes to much lower hardness and smaller size of WC combined with more significant chemical degradation of carbide. When cutting TC4 using PCD tool, notch wear was the most significant wear pattern which was not found when cutting the TMCs. However, chipping, adhesive wear and crater wear were much milder when compared to the cutting of titanium matrix composite. Due to the absence of abrasive wear when cutting TC4, the generated titanium carbide on the PCD protected the tool from fast wear, which caused that the tool life for TC4 was 6-10 times longer than that for TMCs.
