Experimental and Numerical Study of Edge Defects When Turning 17vol.% SiCp/2009Al Composites

Abstract

In this work, a three-dimensional large-deformation thermo-elastic-plastic finite element model for oblique cutting was established to analyze edge defects during the machining of 17vol.% SiCp/2009Al composites. The formation process of edge defects at the workpiece exit during turning was investigated, and the influence of depth of cut, feed rate, and spindle speed on the edge defect sizes at the workpiece exit was explored. The results show that a negative deformation plane began to form as the cutting tool approached the exit end of cut, and the resultant cracks propagated towards the negative shear deformation plane, which led to workpiece edge defects. In addition, the size of edge defects increased with increasing depth of cut and feed rate, while the spindle speed had less influence on the size of edge defects. The numerical results of the effects of cutting parameters on edge defects were also compared to those of the turning experimental data, and were found to be in reasonable agreement.