Modeling and simulation of tool-chip interface friction in cutting Al/SiCp composites based on a three-phase friction model

摘要

Al/SiCp composite machining is considerably difficult owing to the presence of hard particles that result in complex friction at the tool-chip interface. To provide a more comprehensive understanding of the friction at the tool-chip interface in the machining of Al/SiCp composites, this study developed a three-phase friction model that considered the influence of matrix adhesion, two-body abrasion and three-body rolling. Then, to improve the accuracy of the simulation in Al/SiCp composite machining, a finite element (FE) model of randomly distributed round particles was developed by incorporating the three-phase friction model. The simulated chip formation and the cutting force based on the proposed FE model were compared to the experimental results and used to verify the three-phase friction model. The results indicated that two-body sliding, three-body rolling, and matrix sticking are three forms of contact that determined the tool-chip interface friction. The simulated values of the cutting force based on the proposed friction model follow a similar trend and were in good agreement with the experimental magnitudes. In addition, chip formation simulations at different stages in Al/SiCp composites machining were studied, and the chip morphology of the cutting simulation was consistent with the experiments that could be categorized as a saw-toothed chip.