Abstract SiC particle reinforced aluminum matrix (SiCp/Al) composite has been one of the key light metal matrix composites, which is widely used in aerospace and electronics industries due to its excellent material properties. However, the abrasive particles within the materials easily lead to severe tool wear during machining, and the subsequent machining-induced subsurface damage (SSD) will significantly affect the fatigue properties of composite structures. In this paper, an analytical model considering the effects of reinforced particle, thermal-mechanical coupling, and tool wear is first proposed to predict the SSD depth during cutting of SiCp/Al composites. The two-body abrasion and three-body rolling mechanisms are introduced to describe the effects of the particles on the tool-chip interface friction. The mechanical stress and thermal stress induced by mechanical load and thermal load, respectively are simultaneously taken into account. Meanwhile, the tool wear is considered in modeling of friction characteristic of tool flank-workpiece. The SSD depth is evaluated as a measure of variation in microhardness along the depth normal to the cross-section of the machined surface. The correctness of the proposed model was validated by the orthogonal cutting experiments of SiCp/Al composites under different tool wear values and feed rates. A good agreement is found by comparing the predicted and experimental results, which proves that the proposed model can accurately predict the SSD depth with an error of 7.8% in average. Furthermore, the results indicate that even a new tool is used, the SSD depth can reach to hundred micros level during machining of SiCp/Al composites, which is significantly greater than homogeneous metal machining.

中文翻译：

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SiCp/Al复合材料加工中亚表面损伤深度的解析建模

摘要 碳化硅颗粒增强铝基（SiCp/Al）复​​合材料已成为重要的轻金属基复合材料之一，因其优异的材料性能而广泛应用于航空航天和电子行业。然而，材料内部的磨粒在加工过程中容易导致刀具严重磨损，后续加工引起的次表面损伤（SSD）将显着影响复合结构的疲劳性能。在本文中，首先提出了一种考虑增强颗粒、热机械耦合和刀具磨损影响的分析模型，用于预测 SiCp/Al 复合材料切割过程中的 SSD 深度。引入二体磨损和三体滚动机制来描述颗粒对刀具-切屑界面摩擦的影响。同时考虑了分别由机械载荷和热载荷引起的机械应力和热应力。同时，在刀具后刀面-工件摩擦特性建模中考虑了刀具磨损。SSD 深度被评估为显微硬度沿垂直于加工表面横截面的深度变化的量度。通过SiCp/Al复合材料在不同刀具磨损值和进给率下的正交切削实验验证了所提出模型的正确性。通过比较预测结果和实验结果发现了很好的一致性，证明所提出的模型可以准确预测SSD深度，平均误差为7.8%。此外，结果表明，即使使用了新工具，