Machining of Metal Matrix Composite - process modelling, tool wear and surface integrity

金属基复合材料加工 - 工艺建模、刀具磨损和表面完整性

• 批准号: RGPIN-2015-04030
• 负责人: Kishawy, Hossam
• 金额: $ 1.82万
• 依托单位: University of Ontario Institute of Technology
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2018
• 资助国家: 加拿大
• 起止时间: 2018-01-01 至 2019-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=655686
• 关键词: Machining; Metal; Matrix; Composite; process

During the past decades, Metal Matrix Composites (MMCs) have received considerable interests in several manufacturing sectors including the automotive and aerospace industries which represent a major sector of the Canadian manufacturing economy. MMCs possess superior physical and mechanical properties compared to non-reinforced alloys. Therefore, they are being considered as a replacement material for the conventional alloys in many engineering applications. Their unique physical properties give them a great potential; however, MMCs face challenges in order to have a wide spread MMCs substitution for monolithic materials. The presence of abrasive reinforcements in the ductile matrix causes severe tool wear and premature tool failure during machining operation. Although efforts have been made to produce MMCs parts by casting, or hot forging, the resulted near net-shape products still have to be machined into the final shape and dimension with the required accuracy. Cracking and debonding of the reinforcement particles are the significant damage modes of machined surface and also the subsurface damage assessment is critical for machined components subjected to fatigue, especially in critical application such as aerospace. The changes in the machined surface physical properties and machining induced residual stresses are attributed to both mechanical as well as thermal load (heat generated). One way to overcome this challenge is by reducing/eliminating the harmful effect of tool wear. The previous successful application of self-propelled rotary tool in cutting other difficult to cut materials has made it a good candidate for better control of tool wear and tool life when cutting MMC.***          In view of the growing application of these materials, the detailed study of their machined surface integrity and improvement of their cutting process efficiency is required. This study will focus on the above mentioned challenges through detailed surface integrity study of machined MMC surfaces and provide the needed knowledge and expertise to enable the wide use of this material in several Canadian industries.  **

过去，金属基复合材料 (MMC) 在多个制造业领域引起了广泛关注，其中包括汽车和航空航天业，这些领域是加拿大制造业经济的主要领域，因此与非增强合金相比，MMC 具有优异的物理和机械性能。在许多工程应用中，它们被认为是传统合金的替代材料，其独特的物理特性赋予它们巨大的潜力；然而，MMC 面临着广泛替代整体材料的挑战。延性基体中磨料增强材料的存在会导致机械加工过程中严重的刀具磨损和过早的刀具失效，尽管人们已经通过铸造或热锻对MMC零件进行了努力，但所得到的近净形产品仍然需要机械加工成。具有所需精度的最终形状和尺寸，增强颗粒的开裂和脱粘是加工表面的重要损伤模式，并且表面下损伤评估对于遭受疲劳的加工部件至关重要，特别是在关键应用中，例如机械加工表面物理特性和加工引起的残余应力的变化归因于机械负荷和热负荷（产生的热量），克服这一挑战的方法之一是减少/消除刀具磨损的有害影响。自走式旋转刀具在切削其他难切削材料中的成功应用，使其成为切削MMC时更好地控制刀具磨损和刀具寿命的良好候选者。***        鉴于这些材料的应用不断增长，详细的研究需要提高其加工表面的完整性并提高其切削加工效率。本研究将通过对加工 MMC 表面进行详细的表面完整性研究来重点解决上述挑战，并提供所需的知识和专业知识，以实现该材料在多个领域的广泛使用。加拿大工业。