Machining of SiCp/Al Composites: Effect of Tool Corner Radius on Residual Stresses, Cutting Force and Temperature

Abstract

SiCp/Al composite is widely used in the aerospace, electronics and automobile industries due to its ultrahigh strength and wear resistance. Surface integrity in the machining process can be influenced by tool corner radius. A finite element model is developed by DEFORM-2D to study on the effect of tool corner radius on residual stresses, cutting force and temperature in machining SiCp/Al composite process. The results show the large corner radius can improve cutting force, but hardly influence cutting temperature. Meanwhile, value of residual stresses is influenced by tool corner radius, but distribution of residual stress is not. The larger corner radius is, the greater the curve fluctuation of residual stresses is. And the large tool corner radius can effectively improve surface residual compressive stress.