In this paper, a finite element (FE) cutting model for particle-reinforced metal matrix composites (PRMMCs) considering material damage was developed to predict SiC particle failure, cutting forces, and machined surface topography in SiC_p/Al composite machining, and to analyze the dynamic mechanisms of chip formation and particle failure evolution. The validity of the simulation model was verified by comparing the simulation results with the cutting forces and surface topography obtained from the milling machining experiments. It was found that complex stress-strain fields exist in SiC_p/Al composites with mesoscopic non-homogeneous structures, and alternating reticulation of tensile and compressive stress between particles was observed; particle failure due to tool-workpiece interaction exists in both direct and indirect ways; particle failure and local chip deformation during machining affect surface topography and chip shaping, resulting in serrated chips, pitting on the machined surface, and residual particle fragments.

在本文中，开发了一种考虑材料损伤的颗粒增强金属基复合材料 (PRMMC) 的有限元 (FE) 切削模型，以预测 SiC _p / Al 复合材料加工中的SiC 颗粒失效、切削力和加工表面形貌，并分析切屑形成和颗粒失效演化的动力学机制。通过将仿真结果与铣削加工实验获得的切削力和表面形貌进行比较，验证了仿真模型的有效性。发现SiC _p中存在复杂的应力-应变场/Al 复合材料具有细观非均质结构，并观察到颗粒之间拉应力和压应力的交替网状结构；由于工具-工件相互作用导致的颗粒失效以直接和间接方式存在；加工过程中的颗粒失效和局部切屑变形会影响表面形貌和切屑成形，导致锯齿状切屑、加工表面点蚀和残留颗粒碎片。