Influence of Cutting Parameters on the Surface Quality of High Volume Fraction SiCp/Al2024 Composite

This paper studies the milling process of SiCp/Al2024 composite with high volume fraction and large particle size. The milling mechanism of SiCp/Al2024 composite is analyzed. The influence of cutting depth and feed per tooth on surface quality is analyzed. It reveals the influence of the feed per tooth on the subsurface damage of the workpiece. The results show that in the milling process of high volume fraction SiCp/Al2024 composite, because the cutting edge radius is much larger than the particle radius, the main form of particle removal is crushing. The surface defects of the workpiece mainly include pits, cracks, scratches and indentations. Appropriately increasing the depth of cut can improve the surface quality of the workpiece. The increase in feed per tooth will result in increased surface defects of the workpiece and deterioration of surface quality. When the feed per tooth increases from 4 μm to 8 μm, the thickness of the subsurface damage layer of the workpiece increases from 47.7 to 60.5 μm. The ratio between the minimum cutting thickness of the SiCp/Al2024 composite and the radius of the blunt circle should be less than 8%.