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<p>Continuous fiber–reinforced metal matrix composites (CFMMCs) have garnered the significant attention in aerospace and defense applications due to their high specific strength, excellent high-temperature resistance, creep resistance, fatigue resistance, and lightweight advantages. However, the substantial mechanical property disparity between the plastic metal matrix and brittle fibers leads to pronounced defects during the conventional grinding process, including matrix smearing, fiber fracture, and pull-out. High-speed grinding (HSG) process serves as a key technology for achieving precise machining of difficult-to-cut materials (e.g., metal matrix composites), demonstrating substantial potential for achieving low-damage processing of CFMMCs. This investigation systematically explored the matrix-fiber coupled removal mechanisms in SiC fiber-reinforced TC17 titanium matrix composites (SiC<sub>f</sub>/TC17) through single CBN grain across varying fiber orientation angles (<i>θ</i><sub>f</sub> = 0°, 30°, 60°, 90°). The study focused on elucidating the coupled effect of maximum undeformed chip thickness (<i>a</i><sub>gmax</sub>) and fiber embedment depth (<i>h</i><sub>e</sub>) on fiber removal damage. The research results showed that (1) the characteristic damages of SiC<sub>f</sub>/TC17 across all <i>θ</i><sub>f</sub> exhibited matrix smearing, fiber surface micro-fragmentation, fiber macro-fragmentation, fiber macro-fracture, and pull-out. At <i>θ</i><sub>f</sub> = 0°, there were distinctive damage features including matrix lateral flow distortion and fiber edge chipping. At <i>θ</i><sub>f</sub> = 30°, 60°, and 90°, material removal behaviors demonstrated significant similarity. (2) Large-dimension fibers (110&#xa0;μm diameter) of SiC<sub>f</sub>/TC17 exhibited multi-mode damage characteristics dependent on <i>h</i><sub>e</sub>. Three progressive damage modes emerged with <i>h</i><sub>e</sub> decreasing across all <i>θ</i><sub>f</sub>: mode I, fiber surface micro-fragmentation; mode II, fiber fragmentation accompanied by W core exposure/deformation/cut off; mode III, fiber macro-fracture or pull-out. (3) Reducing <i>a</i><sub>gmax</sub> can effectively lower the critical <i>h</i><sub>e</sub> for the transformation of fiber removal damage modes. At <i>θ</i><sub>f</sub> = 90°, when <i>a</i><sub>gmax</sub> decreased from 0.8 to 0.1 μm, the critical <i>h</i><sub>e</sub> for mode I to mode II transition decreased from 89.6 to 82.5 μm, and for mode II to mode III transition decreased from 77.3 to 67.1 μm.</p>

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Material removal mechanisms during high-speed grinding SiCf/TC17 considering anisotropy and fiber embedment depth with a single CBN grain

  • 期刊论文

  • 发表日期：

    2025年8月13日

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  • Shandong Feng,
  • Yumin Wang,
  • Tao Chen,
  • Wenfeng Ding,
  • Biao Zhao

摘要

Continuous fiber–reinforced metal matrix composites (CFMMCs) have garnered the significant attention in aerospace and defense applications due to their high specific strength, excellent high-temperature resistance, creep resistance, fatigue resistance, and lightweight advantages. However, the substantial mechanical property disparity between the plastic metal matrix and brittle fibers leads to pronounced defects during the conventional grinding process, including matrix smearing, fiber fracture, and pull-out. High-speed grinding (HSG) process serves as a key technology for achieving precise machining of difficult-to-cut materials (e.g., metal matrix composites), demonstrating substantial potential for achieving low-damage processing of CFMMCs. This investigation systematically explored the matrix-fiber coupled removal mechanisms in SiC fiber-reinforced TC17 titanium matrix composites (SiCf/TC17) through single CBN grain across varying fiber orientation angles (θf = 0°, 30°, 60°, 90°). The study focused on elucidating the coupled effect of maximum undeformed chip thickness (agmax) and fiber embedment depth (he) on fiber removal damage. The research results showed that (1) the characteristic damages of SiCf/TC17 across all θf exhibited matrix smearing, fiber surface micro-fragmentation, fiber macro-fragmentation, fiber macro-fracture, and pull-out. At θf = 0°, there were distinctive damage features including matrix lateral flow distortion and fiber edge chipping. At θf = 30°, 60°, and 90°, material removal behaviors demonstrated significant similarity. (2) Large-dimension fibers (110 μm diameter) of SiCf/TC17 exhibited multi-mode damage characteristics dependent on he. Three progressive damage modes emerged with he decreasing across all θf: mode I, fiber surface micro-fragmentation; mode II, fiber fragmentation accompanied by W core exposure/deformation/cut off; mode III, fiber macro-fracture or pull-out. (3) Reducing agmax can effectively lower the critical he for the transformation of fiber removal damage modes. At θf = 90°, when agmax decreased from 0.8 to 0.1 μm, the critical he for mode I to mode II transition decreased from 89.6 to 82.5 μm, and for mode II to mode III transition decreased from 77.3 to 67.1 μm.