Finite element and experimental studies of the formation mechanism of edge defects during machining of SiCp/Al composites

• A multi-particle microfinite element model of SiCp/Al composites is developed to predicted formation mechanism of edge defects.
• The impact and cutting depth on the sizes of edge defects is the main factor.
• Predicted edge defects agree well with experimental results.

In this paper, a multi-particle microfinite element model with a random particle distribution in SiCp/Al composites was developed using ABAQUS software. The formation mechanism of edge defects near the exit of orthogonal cutting was analyzed, and the effects of cutting parameters on the sizes of edge defects were investigated. The results indicate that both the brittle fracture of SiC particles and the plastic flow of Al matrix occur in the process of the edge defects formation. Additionally, the cutting speed has little effect on the sizes of edge defects but the cutting depth has a significant effect on the height and length of edge defects. The numerical results were also compared to the orthogonal cutting experimental data and found to be in reasonable agreement.