PSI - Issue 37

Jin Kim et al. / Procedia Structural Integrity 37 (2022) 282–291 Kim et al./ Structural Integrity Procedia 00 (2021) 000 – 000

290

9

Fig. 5 (a) 3D oblique turning simulation results of CT and UAT for 217XG, (b) average net cutting forces comparison between experiment and simulation and (c) residual stresses comparison between CT and UAT for 217XG 5. Conclusion Experimental analysis of CT and UAT (3D elliptical mode, tangential/radial/feed: 28/7/9 µm) of micro-SiC/Al 2124 composite with two different volume fractions (217XG: 17%, 225XE: 25%) and particle sizes (217XG: <0.3 µm, 225XE: <3 µm) was implemented using cemented carbide tools (0.4 and 0.8 mm radius). CT using the PCD tool for both composites was also implemented for tool validation. 3D finite element (FE) simulation modelling was developed for numerical validation. The summarised conclusions are: • The amount of tangential cutting force reduction in UAT compared to CT increased at lower cutting speed, and higher depth-of-cut if no severe tool wear occurs. • The average tangential cutting forces were reduced in UAT using carbide tools by 60.5% and 29.5% for 217XG and 225XE, respectively. • Surface roughness was improved in UAT by 33% and 52.5% for 217XG and 225XE, respectively. • CT using carbide tool distributes more cutting forces in the radial direction than tangential direction compared to PCD tool. • 3D FE simulation with matched Johnson-Cook material parameters can describe the macroscopic oblique CT and UAT process of SiCp/Al composites.