A microstructure-based finite element modelling of the surface defect formation in the cutting of SiCp/Al composites

Understanding the cutting process of particle reinforced aluminum matrix composites is important for a more appropriate application of the composites. However, in the previous finite element modeling, the reinforcement particles, such as SiC, are generally treated as spheres. Such a simplification is inconsistent with the actual geometries of the particles whose shapes are mostly irregular. This paper established a microstructure-based finite element model with the aid of Abaqus/Explicit, imitating the real particle morphologies obtained from the micrographs of SiCp/Al composites. The defect formation mechanisms of the SiC fracture, the cavitation, the pit and the protuberance in machined surfaces of the composites were then investigated and verified by experiment. It was found that the microstructure-based model can more appropriately mimic the cutting of SiCp/Al composites.