Mechanism-Based FE Simulation of Tool Wear in Diamond Drilling of SiCp/Al Composites

Junfeng Xiang; Siqin Pang; Lijing Xie; Feinong Gao; Xin Hu; Jie Yi; Fang Hu

doi:10.3390/ma11020252

Mechanism-Based FE Simulation of Tool Wear in Diamond Drilling of SiC_p/Al Composites

Materials (Basel). 2018 Feb 7;11(2):252. doi: 10.3390/ma11020252.

Authors

Junfeng Xiang¹, Siqin Pang^{2

3}, Lijing Xie^{4

5}, Feinong Gao⁶, Xin Hu⁷, Jie Yi⁸, Fang Hu⁹

Affiliations

¹ School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China. xiang_junfeng@126.com.
² School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China. pangsq@yeah.net.
³ Key Laboratory of Advanced Machining, Beijing Institute of Technology, Beijing 100081, China. pangsq@yeah.net.
⁴ School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China. rita_xie2004@163.com.
⁵ Key Laboratory of Advanced Machining, Beijing Institute of Technology, Beijing 100081, China. rita_xie2004@163.com.
⁶ School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China. 2120170328@bit.edu.cn.
⁷ School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China. 13810438099@163.com.
⁸ School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China. 3120140175@bit.edu.cn.
⁹ School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China. songyl1919@163.com.

Abstract

The aim of this work is to analyze the micro mechanisms underlying the wear of macroscale tools during diamond machining of SiC_p/Al6063 composites and to develop the mechanism-based diamond wear model in relation to the dominant wear behaviors. During drilling, high volume fraction SiC_p/Al6063 composites containing Cu, the dominant wear mechanisms of diamond tool involve thermodynamically activated physicochemical wear due to diamond-graphite transformation catalyzed by Cu in air atmosphere and mechanically driven abrasive wear due to high-frequency scrape of hard SiC reinforcement on tool surface. An analytical diamond wear model, coupling Usui abrasive wear model and Arrhenius extended graphitization wear model was proposed and implemented through a user-defined subroutine for tool wear estimates. Tool wear estimate in diamond drilling of SiC_p/Al6063 composites was achieved by incorporating the combined abrasive-chemical tool wear subroutine into the coupled thermomechanical FE model of 3D drilling. The developed drilling FE model for reproducing diamond tool wear was validated for feasibility and reliability by comparing numerically simulated tool wear morphology and experimentally observed results after drilling a hole using brazed polycrystalline diamond (PCD) and chemical vapor deposition (CVD) diamond coated tools. A fairly good agreement of experimental and simulated results in cutting forces, chip and tool wear morphologies demonstrates that the developed 3D drilling FE model, combined with a subroutine for diamond tool wear estimate can provide a more accurate analysis not only in cutting forces and chip shape but also in tool wear behavior during drilling SiC_p/Al6063 composites. Once validated and calibrated, the developed diamond tool wear model in conjunction with other machining FE models can be easily extended to the investigation of tool wear evolution with various diamond tool geometries and other machining processes in cutting different workpiece materials.

Keywords: SiCp/Al6063 composites; abrasive-chemical wear; diamond tool; drilling; finite element; graphitization.