ABSTRACT Machining of novel light weight 7075 aluminum alloy reinforced with thin-walled hollow ceramic bubbles present a significant challenge to the manufacturing industry. The presence of hollow bubble phase causes poor surface finish and high machining cost. In this paper, an effort has been made to elucidate the mechanics of machining new grade AA7075 syntactic foams through an analytical force model which is the first of its kind for this material. Orthogonal cutting experiments carried out on different volume fraction and bubble size syntactic foams showed an increase in machining forces by up to 500 N with increasing feed (0.02 mm to 0.2 mm) and 200 N with decreasing cutting speed (100 m/min to 25 m/min). The hollow bubble size profoundly influences the plastic deformation behavior of the matrix. Decrease in average ceramic bubble size (0.6 mm to 0.3 mm) causes the machining forces to increase by margin of 65%. It is found that smaller the hollow bubble size and higher its volume fraction, higher will be the magnitude of machining forces. The causes of variation in machining forces is primary attributed to the characteristic bubble burst modes (Mode 1 and Mode 2) that alters the effective load transfer mechanism with 7075 matrix and its plasticity.

中文翻译：

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含薄壁陶瓷气泡的新型AA7075泡沫的加工

摘要用薄壁空心陶瓷气泡增强的新型轻质 7075 铝合金的加工对制造业提出了重大挑战。中空气泡相的存在导致表面光洁度差和加工成本高。在本文中，已努力通过分析力模型来阐明加工新牌号 AA7075 复合泡沫材料的力学原理，这是该材料的首创。对不同体积分数和气泡尺寸复合泡沫进行的正交切割实验表明，随着进给量的增加（0.02 毫米到 0.2 毫米），加工力增加高达 500 N，而随着切削速度的降低（100 m/min 到 25 m），加工力增加了 200 N /分钟）。中空气泡的大小对基体的塑性变形行为有着深远的影响。平均陶瓷气泡尺寸减小 (0. 6 毫米到 0.3 毫米）导致加工力增加 65%。发现中空气泡尺寸越小，其体积分数越高，加工力的大小就越大。加工力变化的原因主要归因于特征气泡破裂模式（模式 1 和模式 2），该模式改变了 7075 基体的有效载荷传递机制及其塑性。