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<p>To address the challenges of interfacial delamination and surface damage in heterogeneous laminated composites caused by material property mismatch and multiphase interface interactions, this study investigates TC4‑6061Al and TC4‑SiCp/Al laminates. An orthogonal cutting model incorporating multiphase interface damage mechanisms is developed, and a quantitative surface integrity evaluation method based on the area damage ratio (P<sub>ADR</sub>) is proposed. The results show that the established model accurately captures the entire interfacial degradation process, from damage initiation and stiffness reduction to final debonding. Interfacial failure is primarily attributed to localized stress concentrations induced by material mismatch. The cutting sequence plays a decisive role in interfacial morphology. Machining from the softer to the harder layer fully utilizes the rigid support provided by the underlying material, effectively suppresses interface collapse and delamination, and thereby achieves better interfacial integrity and process stability. The proposed P<sub>ADR</sub> method enables quantitative characterization of interfacial surface damage, and the results demonstrate that the damaged area exhibits a nonlinear increasing trend with increasing cutting depth. Furthermore, it reveals that the brittle removal of SiC reinforcing particles is the dominant factor aggravating surface damage. This research provides theoretical insights and a practical evaluation basis for high‑precision, low‑damage machining of heterogeneous laminated composites.</p>

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Investigation on Failure Mechanisms and Damage Assessment at the Cutting Interface of Ti–Al Laminated Composites

  • 期刊论文

  • 发表日期：

    2026年7月9日

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  • Weicheng Guo,
  • Shijin Luo,
  • Man Ren,
  • Miaoxian Guo,
  • Zishan Ding

摘要

To address the challenges of interfacial delamination and surface damage in heterogeneous laminated composites caused by material property mismatch and multiphase interface interactions, this study investigates TC4‑6061Al and TC4‑SiCp/Al laminates. An orthogonal cutting model incorporating multiphase interface damage mechanisms is developed, and a quantitative surface integrity evaluation method based on the area damage ratio (PADR) is proposed. The results show that the established model accurately captures the entire interfacial degradation process, from damage initiation and stiffness reduction to final debonding. Interfacial failure is primarily attributed to localized stress concentrations induced by material mismatch. The cutting sequence plays a decisive role in interfacial morphology. Machining from the softer to the harder layer fully utilizes the rigid support provided by the underlying material, effectively suppresses interface collapse and delamination, and thereby achieves better interfacial integrity and process stability. The proposed PADR method enables quantitative characterization of interfacial surface damage, and the results demonstrate that the damaged area exhibits a nonlinear increasing trend with increasing cutting depth. Furthermore, it reveals that the brittle removal of SiC reinforcing particles is the dominant factor aggravating surface damage. This research provides theoretical insights and a practical evaluation basis for high‑precision, low‑damage machining of heterogeneous laminated composites.