Mechanism of material removal and chip formation of alumina dispersion strengthened copper in micro-milling

Abstract

Alumina dispersion-strengthened copper (ADSC), as a representative particle-reinforced metal matrix composite (PRMMC), exhibits superior wear resistance and high strength. However, challenges arise in their processability because of the non-uniform material properties of biphasic materials. In particular, limited research has been conducted on the reinforcement mechanism and behavior of particles during material cutting deformation of PRMMC with nanoscale particles. In this study, a cutting simulation model for ADSC was established, separating the nanoscale reinforcement particles from the matrix. This model was utilized to analyze the interactions among particles, matrix, and tool during the cutting process, providing insights into chip formation and fracture. Particles with high strength and hardness are more prone to storing stress concentrations, anchoring themselves at grain boundaries to resist grain fibration, thereby influencing the stress distribution in the cutting deformation zone. Stress concentration around the particles leads to the formation of discontinuous chips, indicating that ADSC with high-volume fractions of particle (VFP) exhibits low cutting continuity, which is consistent with the results of cutting experiments. The tool tip that is in contact with particles experiences stress concentration, thereby accelerating tool wear. Cutting ADSC with 1.1% VFP results in tool blunting, which increases the radius of cutting edge from 0.5 to 1.9 μm, accompanied with remarkable coating delamination and wear. Simulation results indicate that the minimum uncut chip thickness increases from 0.04 to 0.07 μm as VFP increases from 0.3% to 1.1%. In conjunction with scratch experiments, MUCT increases with the augmentation of VFP. Computational analysis of the specific cutting force indicates that particles contribute to the material’s size effect. The results of this study provide theoretical guidance for practical engineering machining of ADSC, indicating its great importance for the process design of components made from ADSC.

Graphical abstract

Keywords

alumina dispersion-strengthened copper / particle-reinforced metal matrix composites / material removal mechanism / micro-milling / chip formation / minimum uncut chip thickness

References

[1] Güler O, Varol T, Alver Ü, Canakci A. Effect of Al₂O₃ content and milling time on the properties of silver coated Cu matrix composites fabricated by electroless plating and hot pressing. Materials Today Communications, 2020, 24: 101153

[2] Shen D P, Gao P F, He Y X, Gong J P, Du J W. A Cu-Al₂O₃ composite with ultrahigh tensile strength prepared by high-pressure torsion. Journal of Materials Engineering and Performance, 2022, 31(11): 9425–9430

[3] Guo X H, Song K X, Liang S H, Wang X, Zhang Y M. Effect of Al₂O₃ particle size on electrical wear performance of Al₂O₃/Cu composites. Tribology Transactions, 2016, 59(1): 170–177

[4] Lin H R, Guo X H, Song K X, Feng J, Li S L, Zhang X F. Synergistic strengthening mechanism of copper matrix composite reinforced with nano-Al₂O₃ particles and micro-SiC whiskers. Nanotechnology Reviews, 2021, 10(1): 62–72

[5] Zhang X H, Zhang Y, Tian B H, An J C, Zhao Z, Volinsky A A, Liu Y, Song K X. Arc erosion behavior of the Al₂O₃-Cu/(W, Cr) electrical contacts. Composites Part B: Engineering, 2019, 160: 110–118

[6] BaigA, Gamzina D, BarchfeldR, ZhaoJ F, Domier C, Spear A, Barnett L R, LuhmannN C. 220 GHz ultra wide band TWTA: nano CNC fabrication and RF testing. In: Proceedings of 2013 IEEE 14th International Vacuum Electronics Conference. Paris: IEEE, 2013, 1–2

[7] Ružić J, Stašić J, Rajković V, Božić D. Strengthening effects in precipitation and dispersion hardened powder metallurgy copper alloys. Materials & Design, 2013, 49: 746–754

[8] Baig A, Gamzina D, Kimura T, Atkinson J, Domier C, Popovic B, Himes L, Barchfeld R, Field M, Luhmann N C. Performance of a nano-CNC machined 220-GHz traveling wave tube amplifier. IEEE Transactions on Electron Devices, 2017, 64(5): 2390–2397

[9] Dang J Q, Zhang H, Ming W W, An Q L, Chen M. New observations on wear characteristics of solid Al₂O₃/Si₃N₄ ceramic tool in high speed milling of additive manufactured Ti6Al4V. Ceramics International, 2020, 46(5): 5876–5886

[10] Zhou X Y, Yu T Y, Wang G Z, Guo R Y, Fu Y X, Sun Y Z, Chen M J. Tool wear classification based on convolutional neural network and time series images during high precision turning of copper. Wear, 2023, 522: 204692

[11] Dang J Q, Cai X J, Yu D D, An Q L, Ming W W, Chen M. Effect of material microstructure on tool wear behavior during machining additively manufactured Ti6Al4V. Archives of Civil and Mechanical Engineering, 2020, 20(1): 4

[12] Ge Y F, Xu J H, Huan H X. Tool wear during high speed turning in situ TiCp/TiBw hybrid reinforced Ti-6Al-4V matrix composite. Chinese Journal of Aeronautics, 2016, 29(5): 1425–1435

[13] Josyula S K, Reddy Narala S K. Study of TiC particle distribution in Al-MMCs using finite element modeling. International Journal of Mechanical Sciences, 2018, 141: 341–358

[14] Jing L, Niu Q L, Dang J Q, An Q L, Wang C H, Zou F, Li C P, Li P N, Yue W H, Ko T J. Milling performance evaluation and cooling/lubrication mechanism of Al-50wt% Si alloy based on various environmentally sustainable manufacturing strategies. The International Journal of Advanced Manufacturing Technology, 2022, 122(2): 1023–1040

[15] Sun W, Duan C Z, Yin W D. Modeling of force and temperature in cutting of particle reinforced metal matrix composites considering particle effects. Journal of Materials Processing Technology, 2021, 290: 116991

[16] Umer U, Kishawy H, Ghandehariun A, Xie L J, Al-Ahmari A. On modeling tool performance while machining aluminum-based metal matrix composites. The International Journal of Advanced Manufacturing Technology, 2017, 92(9–12): 3519–3530

[17] Yin W D, Duan C Z, Sun W, Wei B. Analytical model of cutting temperature for workpiece surface layer during orthogonal cutting particle reinforced metal matrix composites. Journal of Materials Processing Technology, 2020, 282: 116643

[18] Wu Q, Si Y, Wang G S, Wang L. Machinability of a silicon carbide particle-reinforced metal matrix composite. RSC Advances, 2016, 6(26): 21765–21775

[19] Zhu Y, Kishawy H A. Influence of alumina particles on the mechanics of machining metal matrix composites. International Journal of Machine Tools & Manufacture, 2005, 45(4–5): 389–398

[20] Liu C, Xu W W, Jin Y, Jiang X G, Yang T. Mechanistic force modeling in drilling of SiCp/Al matrix composites considering a comprehensive abrasive particle model. The International Journal of Advanced Manufacturing Technology, 2020, 109(1–2): 421–442

[21] DuanC Z, Sun W, FuC, ZhangF Y. Modeling and simulation of tool-chip interface friction in cutting Al/SiCp composites based on a three-phase friction model. International Journal of Mechanical Sciences, 2018, 142–143: 384–396

[22] Lu S J, Li Z Q, Zhang J J, Zhang C Y, Li G, Zhang H J, Sun T. Coupled effect of tool geometry and tool-particle position on diamond cutting of SiCp/Al. Journal of Materials Processing Technology, 2022, 303: 117510

[23] Du Y S, Lu M M, Lin J Q, Yang Y K. Experimental and simulation study of ultrasonic elliptical vibration cutting SiCp/Al composites: chip formation and surface integrity study. Journal of Materials Research and Technology, 2023, 22: 1595–1609

[24] Wu H, Xu W C, Shan D B, Wang X J, Guo B, Jin B C. Micromechanical modeling of damage evolution and fracture behavior in particle reinforced metal matrix composites based on the conventional theory of mechanism-based strain gradient plasticity. Journal of Materials Research and Technology, 2023, 22: 625–641

[25] Zhang F Y, Lin Z A, Qiu H, Zhou X Y, Zhang T J. Effects of cutting conditions on the surface formation mechanism in cutting of in-situ (TiBw+TiCP)/Ti composite. Journal of Materials Processing Technology, 2023, 318: 118035

[26] Rajkovic V, Bozic D, Jovanovic M T. Effects of copper and Al₂O₃ particles on characteristics of Cu-Al₂O₃ composites. Materials & Design, 2010, 31(4): 1962–1970

[27] Rajkovic V, Bozic D, Stasic J, Wang H W, Jovanovic M T. Processing, characterization and properties of copper-based composites strengthened by low amount of alumina particles. Powder Technology, 2014, 268: 392–400

[28] Strojny-Nędza A, Pietrzak K, Węglewski W. The influence of Al₂O₃ powder morphology on the properties of Cu-Al₂O₃ composites designed for functionally graded materials (FGM). Journal of Materials Engineering and Performance, 2016, 25(8): 3173–3184

[29] Wu Q, Xu W X, Zhang L C. Machining of particulate-reinforced metal matrix composites: an investigation into the chip formation and subsurface damage. Journal of Materials Processing Technology, 2019, 274: 116315

[30] Liu C, Li C, Xu W W, Gao L. Variation characteristics of machinability in drilling of SiC particle reinforced aluminum matrix (SiCp/Al) composite with a wide range of particle volume fractions. The International Journal of Advanced Manufacturing Technology, 2022, 121(9–10): 6285–6302

[31] Wang G Z, Yu T Y, Zhou X Y, Guo R Y, Chen M J, Sun Y Z. Material removal mechanism and microstructure fabrication of GDP during micro-milling. International Journal of Mechanical Sciences, 2023, 240: 107946

[32] Sun W, Duan C Z, Yin W D. Chip formation mechanism in machining of Al/SiCp composites based on analysis of particle damage. Journal of Manufacturing Processes, 2021, 64: 861–877

[33] Teng X Y, Chen W Q, Huo D H, Shyha I, Lin C. Comparison of cutting mechanism when machining micro and nano-particles reinforced SiC/Al metal matrix composites. Composite Structures, 2018, 203: 636–647

[34] Bao Y J, Zhang X, Lu S X, Zhang H Z. Investigation on the removal characteristics of single-point cutting high-volume fraction SiCp/Al composites. The International Journal of Advanced Manufacturing Technology, 2022, 118(3–4): 881–894

[35] Yin W D, Duan C Z, Li Y J, Miao K Q. Dynamic cutting force model for cutting SiCp/Al composites considering particle characteristics stochastic models. Ceramics International, 2021, 47(24): 35234–35247

[36] Liu Q, Liao Z R, Axinte D. Temperature effect on the material removal mechanism of soft-brittle crystals at nano/micron scale. International Journal of Machine Tools & Manufacture, 2020, 159: 103620

[37] Liu Q, Liao Z R, Cheng J, Xu D D, Chen M J. Mechanism of chip formation and surface-defects in orthogonal cutting of soft-brittle potassium dihydrogen phosphate crystals. Materials & Design, 2021, 198: 109327

[38] Wang G Z, Yu T Y, Zhou X Y, Guo R Y, Chen M J. Investigation on minimum uncut chip thickness and size effect in micro milling of glow discharge polymer (GDP). Journal of Manufacturing Processes, 2022, 84: 786–797

[39] Kim K W, Lee W Y, Sin H. A finite element analysis for the characteristics of temperature and stress in micro-machining considering the size effect. International Journal of Machine Tools & Manufacture, 1999, 39(9): 1507–1524

[40] Aurich J C, Bil H. 3D finite element modelling of segmented chip formation. CIRP Annals, 2006, 55(1): 47–50

[41] Chen N, Chen M J, Wu C Y, Pei X D, Qian J, Reynaerts D. Research in minimum undeformed chip thickness and size effect in micro end-milling of potassium dihydrogen phosphate crystal. International Journal of Mechanical Sciences, 2017, 134: 387–398

[42] Feng G, Sagapuram D. A strong basis for friction as the origin of size effect in cutting of metals. International Journal of Machine Tools & Manufacture, 2021, 168: 103741

[43] Guo R Y, Yu T Y, Chen M J. Frictional behavior of tool-workpiece on surface quality of glow discharge polymer during micro-milling. Wear, 2023, 522: 204707

[44] Zhang X H, Li X X, Chen H, Li T B, Su W, Guo S D. Investigation on microstructure and properties of Cu-Al₂O₃ composites fabricated by a novel in-situ reactive synthesis. Materials & Design, 2016, 92: 58–63

[45] Lu T X, Chen C G, Li P, Zhang C Z, Han W H, Zhou Y, Suryanarayana C, Guo Z M. Enhanced mechanical and electrical properties of in situ synthesized nano-tungsten dispersion-strengthened copper alloy. Materials Science and Engineering: A, 2021, 799: 140161

[46] Guo M X, Wang M P, Shen K, Cao L F, Tan W. Tensile fracture behavior characterization of dispersion strengthened copper alloys. Journal of Alloys and Compounds, 2009, 469(1–2): 488–498

RIGHTS & PERMISSIONS

Higher Education Press