Fundamental theory and experimental study on ball milling process of SiCp/Al composites

In order to reveal the influence of cutting parameters on the surface roughness and surface morphology of SiCp/Al composites, the milling experiment of SiCp/Al 2009 composites with volume fraction of 20% was carried out by using polycrystalline diamond ball-end milling cutter. The three-dimensional finite-element modeling and simulation of the milling process are carried out, and the influence of the removal of the matrix and SiC particles on the surface quality of the composite material is expounded. The single-factor experimental design and response surface experimental design were used in the experiment, and the analysis of variance was used to check the dependence of cutting parameters and their interaction, and the prediction model of surface roughness was compared with the actual model. The surface and subsurface morphologies of the workpiece were observed by laser scanning confocal microscope and scanning electron microscope, and the influence of cutting parameters on the surface quality was analyzed. The results show that the milling depth has the greatest influence on the surface roughness, followed by the milling speed, and the feed speed has the least influence on the surface roughness. The optimal value of the surface roughness of milling is 0.034 μm, the machined surface has obvious pits, cracks, burrs, and the subsurface of the workpiece has the phenomenon of particle breakage, pits, and shedding.