The milling simulation and experimental research on high volume fraction of SiC_p/Al

A multi-phase two-dimension finite element model has been developed by using ABAQUS/Explicit in order to describe the effect of reinforcement particles’ existence in SiC_p/Al6063 composites on the machining process. It is used to simulate the high-speed milling process of high volume fraction SiC_p/Al6063 composites. As comparison, the same machining process of matrix Al6063 is simulated with the HEM (homogenous equivalent material) model. These two models are verified with quasi-orthogonal slot milling tests. It is assumed that the variation of predicted milling forces with the feed rate is consistent with the experiments and the prediction error of the peak value of F_y can be controlled within 10 %. Moreover, multi-phase model is helpful for discovering the miscellaneous interactions of matrix, particle and tool and the induced complicated stress distribution in the cutting area, for further obtaining an in-depth understanding of removal mechanism of SiC_p/Al6063 composites.