Investigation on the removal characteristics of single-point cutting high-volume fraction SiCp/Al composites

SiC-reinforced aluminum matrix composites (SiCp/Al composites) are typically difficult-to-machine material, and the irregular SiC diffused in SiCp/Al composites make the surface quality worse. In this paper, a single-point cutting simulation with variable plane cutting depth were conducted for SiCp/Al composite with higher volume fraction (65 Vol%) and aluminum alloy. The surface morphology characteristics of SiCp/Al composites, which mainly include breaking, part breaking, pulling out, protruding, al tearing, and interface debonding, are different from those of aluminum alloy materials. The high-volume SiC lower the surface quality and profile dimensional accuracy of SiCp/Al composites. There are thin and discrete layers covered on the machined surface. Finally, a single-point cutting test, which meets the actual grinding condition, was conducted for 2A12 aluminum alloy, 45% SiCp/Al composite, and 65% SiCp/Al composite. The simulation results are verified by experimental data obtained from the single-point cutting test.