A Review on Machining SiCp/Al Composite Materials

A Review on Machining SiCp/Al Composite Materials

7 January 2024 | Zhigao Chen, Fei Ding, Zhichao Zhang, Qiuyan Liao, Zheng Qiao, Yuan Jin, Mingjun Chen and Bo Wang
This review article by Chen et al. examines the machining of SiCp/Al composite materials, which are widely used in aerospace and electronics industries due to their excellent material properties. However, their machinability is significantly reduced due to the hard and brittle nature of SiC particles. The study covers the processing mechanisms, turning, milling, drilling, grinding, special machining, and hybrid machining characteristics of SiCp/Al composites. It highlights the challenges and existing problems in machining these materials, aiming to enhance their machinability and promote high-quality and efficient processing methods. The introduction discusses the microstructure and performance parameters of SiCp/Al composites, emphasizing the difficulties in machining due to the varying volume fractions of SiC particles. The machining mechanism is explored through finite element modeling and experimental studies, focusing on chip formation, tool wear, and surface quality. The article also reviews the impact of cutting parameters on tool wear and surface roughness, and the effectiveness of different tool materials such as polycrystalline diamond (PCD) and cubic boron nitride (CBN). The turning, milling, drilling, and grinding sections detail the specific challenges and optimal parameters for each machining process. For example, in turning, the use of PCD tools with larger rake angles and tip radii is recommended for high-speed milling to achieve efficient and high-quality surface milling. In drilling, PCD drill bits are preferred for thick-walled and thin-walled workpieces to reduce tool wear and improve surface quality. The special machining section covers unconventional techniques like electrical discharge machining (EDM), electrochemical jet machining (ECJM), and laser processing. These methods are explored for their ability to address the limitations of conventional processes, such as severe tool wear and poor surface finish. The article concludes with a discussion on the future directions and potential improvements in machining SiCp/Al composites.This review article by Chen et al. examines the machining of SiCp/Al composite materials, which are widely used in aerospace and electronics industries due to their excellent material properties. However, their machinability is significantly reduced due to the hard and brittle nature of SiC particles. The study covers the processing mechanisms, turning, milling, drilling, grinding, special machining, and hybrid machining characteristics of SiCp/Al composites. It highlights the challenges and existing problems in machining these materials, aiming to enhance their machinability and promote high-quality and efficient processing methods. The introduction discusses the microstructure and performance parameters of SiCp/Al composites, emphasizing the difficulties in machining due to the varying volume fractions of SiC particles. The machining mechanism is explored through finite element modeling and experimental studies, focusing on chip formation, tool wear, and surface quality. The article also reviews the impact of cutting parameters on tool wear and surface roughness, and the effectiveness of different tool materials such as polycrystalline diamond (PCD) and cubic boron nitride (CBN). The turning, milling, drilling, and grinding sections detail the specific challenges and optimal parameters for each machining process. For example, in turning, the use of PCD tools with larger rake angles and tip radii is recommended for high-speed milling to achieve efficient and high-quality surface milling. In drilling, PCD drill bits are preferred for thick-walled and thin-walled workpieces to reduce tool wear and improve surface quality. The special machining section covers unconventional techniques like electrical discharge machining (EDM), electrochemical jet machining (ECJM), and laser processing. These methods are explored for their ability to address the limitations of conventional processes, such as severe tool wear and poor surface finish. The article concludes with a discussion on the future directions and potential improvements in machining SiCp/Al composites.
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