Machining Simulation of Recrystallized SiC: Failure Mechanisms, Numerical Influences, Tool Dynamics, and Friction Behavior

This paper presents a comprehensive study on the machining simulation of recrystallized silicon carbide (R‐SiC), with a focus on material failure mechanisms, numerical influences, tool kinematics, and frictional behavior. A representative volume of interest was derived from CT data, and a meshing algorithm for CT‐based structures was introduced to generate high‐quality hexahedral meshes. The investigation systematically addresses numerical parameters such as element formulation, density scaling, mesh resolution, and erosion criteria, and benchmarks them against analytical models. To capture process dynamics more accurately, velocity‐dependent friction laws were implemented, while tool compliance was modeled using beam elements with damping parameters to represent bending and vibration effects. The results reveal strong interactions between cutting edge geometry, material strength, and tribological conditions, with direct implications for chip formation, fracture energy, and force prediction. Numerical predictions were validated against experimental data, demonstrating high accuracy. The study provides clear guidelines on suitable numerical approaches, highlights the role of tool rigidity and kinematics in ceramic machining, and establishes a transferable simulation framework. This methodology advances predictive modeling of ceramic machining and lays the foundation for future work on tool wear and process optimization across brittle–hard materials.