An Investigation of Surface Defect Formation in Micro Milling the 45% SiCp/Al Composite

In this paper, an orthogonal cutting simulation on machining 45% SiC/Al composites is presented for develop an in-depth understanding of surface defects in micro milling of the SiCp/Al composites and the associated machining parameters. PCD micro end mill is used with the value of the cutting edge radius close to the SiC particle size. The material removal mechanism and the surface defect formation at three typical cases are analysed. The results indicate the main machined surface defect is affected by the tool-particle interaction location. The half interaction location might lead to the best surface quality, which is proved by cutting trials and experimental observation.