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

作　　者：Chang LIU Chunya WU Xiguang LI Bo HOU Jiahao WU Ruijiang SUN Mingjun CHEN 

机构地区：[1]School of Mechatronics Engineering,Harbin Institute of Technology,Harbin 150001,China [2]State Key Laboratory of Robotics and System,Harbin Institute of Technology,Harbin 150001,China

出　　处：《Frontiers of Mechanical Engineering》2025年第1期27-43,共17页机械工程前沿(英文版)

基　　金：supported by the National Key R&D Program of China(Grant No.2023YFC2413303);the National Natural Science Foundation of China(Grant No.52075128);the Natural Science Foundation of Heilongjiang Province,China(Grant No.YQ2020E013).

摘　　要：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 co

关 键 词：alumina dispersion-strengthened copper particle-reinforced metal matrix composites material removal mechanism MICRO-MILLING chip formation minimum uncut chip thickness 

分 类 号：TP3[自动化与计算机技术—计算机科学与技术]