A model for force prediction in grinding holes of SiCp/Al composites. (September 2019)

• Record Type: Journal Article
• Authors: Lu, Shouxiang; Gao, Hang; Bao, Yongjie; Xu, Qihao
• Is Part Of: International journal of mechanical sciences. Volume 160(2019)
• Page Start: 1
• Page End: 14
• Publication Date: 2019-09
• Subjects: SiCp/Al composites -- Grinding force model -- Single-grit grinding force -- Undeformed chip thickness; Mechanical engineering -- Periodicals; Génie mécanique -- Périodiques; Mechanical engineering; Maschinenbau; Mechanik; Zeitschrift; Periodicals; 621.05
• DOI: 10.1016/j.ijmecsci.2019.06.025
• Languages: English
• ISSNs: 0020-7403

Abstract

Highlights: A novelly method for calculating the undeformed chip thickness and section area of a single abrasive particle under the condition of grinding holes is presented in this paper. A new model for force prediction under hole-grinding condition is established and validated. Within the range of test parameters in this paper, the average prediction deviation of axial force and torque is 7.8% and 5.2% respectively. The conclusions show that the presented model is effective in predicting the grinding force during grinding holes of high volume fraction SiCp/Al composites. Abstract: Excellent mechanical properties make high volume fraction SiCp/Al composites applicable to many important applications. However, the extremely high hardness of the reinforcement SiC particles makes it difficult to machine, especially for the hole-grinding process. In this paper, a new model for predicting the axial force and torque during grinding hole of SiCp/Al composites was developed. Considering the material removal mechanism, the grinding force was divided into three components according to the source, which were the plastic deformation force of matrix material, friction force between abrasive grits and workpiece material, debonding and fracture force of SiC particles, respectively. A novel method for calculating the thickness and cross-sectional area of undeformed chips in grinding holes was proposed to calculate the single-grit grinding force. The axial force and torque of the grinding tool were obtained by calculating the total grinding force of all effective grits. Results of the validated experiments were in good agreement with that of the presented model within the range of test parameters in this paper, with prediction deviation of the axial force and torque of 7.8% and 5.2%, which indicate that the model can be used to optimize process parameters.