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<p>Silicon carbide particle-reinforced aluminum matrix composites (SiC<sub>p</sub>/Al), as a key lightweight structural-functional material for sustainable development in aerospace, new-energy transportation and other fields, are susceptible to high cutting loads, poor surface quality, and surface/subsurface damage during milling because of the pronounced mechanical and thermal mismatch between silicon carbide particles and the Al matrix. Dry milling experiments were carried out on SiC<sub>p</sub>/Al and its corresponding monolithic Al alloy using a three-flute polycrystalline diamond (PCD) end mill to examine how feed per tooth affects surface formation and damage evolution. The cutting speed, axial depth of cut, and cutting width were fixed at 250&#xa0;m/min, 2&#xa0;mm, and 0.25&#xa0;mm, respectively, while feed per tooth was varied from 0.01 to 0.20&#xa0;mm/z. Cutting force, surface roughness, three-dimensional topography, and surface/subsurface damage were compared over a feed-per-tooth range of 0.01–0.20&#xa0;mm/z. The results show that the cutting forces of both materials increase with feed per tooth, whereas SiC<sub>p</sub>/Al consistently exhibits higher force levels and more pronounced force fluctuations. Surface roughness also increases with feed per tooth for both materials. Surface observations show that Al mainly exhibits unstable plastic flow and matrix adhesion-tearing, whereas SiC<sub>p</sub>/Al additionally exhibits particle fracture, local debonding or pull-out, and groove damage. Subsurface observations further reveal more complex particle- and interface-related damage in SiC<sub>p</sub>/Al. These results provide support for parameter optimization and surface integrity control in the milling of SiC<sub>p</sub>/Al composites, thereby further contributing to the economic, environmental and social sustainability of advanced manufacturing of lightweight composite components.</p>

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Effect of feed per tooth on surface formation and damage evolution in milling of SiCp/Al composites

  • 期刊论文

  • 发表日期：

    2026年8月4日

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  • Jianhao Peng,
  • Shiyun Wang,
  • Wenfeng Ding,
  • Xiaole Huang,
  • Biao Zhao,
  • Mohamed Slamani

摘要

Silicon carbide particle-reinforced aluminum matrix composites (SiCp/Al), as a key lightweight structural-functional material for sustainable development in aerospace, new-energy transportation and other fields, are susceptible to high cutting loads, poor surface quality, and surface/subsurface damage during milling because of the pronounced mechanical and thermal mismatch between silicon carbide particles and the Al matrix. Dry milling experiments were carried out on SiCp/Al and its corresponding monolithic Al alloy using a three-flute polycrystalline diamond (PCD) end mill to examine how feed per tooth affects surface formation and damage evolution. The cutting speed, axial depth of cut, and cutting width were fixed at 250 m/min, 2 mm, and 0.25 mm, respectively, while feed per tooth was varied from 0.01 to 0.20 mm/z. Cutting force, surface roughness, three-dimensional topography, and surface/subsurface damage were compared over a feed-per-tooth range of 0.01–0.20 mm/z. The results show that the cutting forces of both materials increase with feed per tooth, whereas SiCp/Al consistently exhibits higher force levels and more pronounced force fluctuations. Surface roughness also increases with feed per tooth for both materials. Surface observations show that Al mainly exhibits unstable plastic flow and matrix adhesion-tearing, whereas SiCp/Al additionally exhibits particle fracture, local debonding or pull-out, and groove damage. Subsurface observations further reveal more complex particle- and interface-related damage in SiCp/Al. These results provide support for parameter optimization and surface integrity control in the milling of SiCp/Al composites, thereby further contributing to the economic, environmental and social sustainability of advanced manufacturing of lightweight composite components.