SiCp/Al composite materials are widely used in various industries such as the aerospace and the electronics industries, primarily due to their excellent material properties. However, their machinability is significantly weakened due to their unique characteristics. Consequently, efficient and precise machining technology for SiCp/Al composite materials has become a crucial research area. By conducting a comprehensive analysis of the relevant research literature from both domestic and international sources, this study examines the processing mechanism, as well as the turning, milling, drilling, grinding, special machining, and hybrid machining characteristics, of SiCp/Al composite materials. Moreover, it summarizes the latest research progress in composite material processing while identifying the existing problems and shortcomings in this area. The aim of this review is to enhance the machinability of SiCp/Al composite materials and promote high-quality and efficient processing methods.

A Review on Machining SiCp/Al Composite Materials

Abstract Sheet metals such as titanium alloys, steel alloys, and aluminum alloys are significant materials due to their importance among everyday life products as well as high-strength applications in aircraft, ships, automobiles, construction, military, and marine purposes. Recently, laser cutting is one of the best and fastest non-conventional methods to cut sheet metals, so it is necessary to understand how laser cutting parameters affect cutting quality. A comprehensive review was presented to investigate how laser cutting parameters affect the cut surface and kerf quality and which parameters affect cutting quality the most. An overview of the advantages of laser cutting when compared to other methods of machining was presented. In addition, a description of the laser cutting method and the different sources of laser were presented with clearing the range of thicknesses of the cut material for each source and their advantages. Also, a description of the properties and the applications of the studied materials were discussed. The performance parameters ofcutting were illustrated in detail by graphs and equations. The research analysis and discussion were discussed in such organized details by tables and graphs which show the full classification of the studied papers. It was found that the best conditions to obtain low surface roughness, small HAZ width, small kerf width, and small kerf angle are using low laser power, high cutting speed, medium gas pressure, high standoff distance, medium pulse frequency, medium pulse width, small nozzle diameter, small thickness, and nitrogen as an assist gas. 

A comprehensive review of studying the influence of laser cutting parameters on surface and kerf quality of metals

Carbon fiber reinforced silicon carbide ceramic matrix composites (Cf/SiC composites) have a wide range of applications in aerospace, nuclear energy, braking systems owing to its excellent mechanical performance. Nevertheless, the hardness, brittleness, heterogeneity, and anisotropy of Cf/SiC composites give rise to difficulties in machining them. In addition, the characterization and formation mechanism of surface damage in the grinding of Cf/SiC composites have not been fully elucidated. The purpose of this paper is to provide a characterization method for surface damage of Cf/SiC composites and an evaluation index for surface edge chipping damage (SECD) through conventional scratching (CS) / ultrasonic vibration assisted scratching (UVAS) tests with single abrasive. Towards revealing the surface damage behavior of Cf/SiC composites during scratching, as well as the impact of fiber orientation on surface damage. The findings indicate that main forms of surface damage of Cf/SiC composites in single abrasive scratching are fiber breakage, fiber fracture-shedding, fiber fracture, fiber-matrix interface debonding, interface fragmentation, matrix cracking, and matrix microcracks. Further, ultrasonic vibration could help to suppress the SECD, and the SECD factor was smallest when scratching along the perpendicular fiber. Furthermore, the fiber orientation can significantly affect the scratching force and cross-sectional area of scratches on Cf/SiC composites via single abrasive scratching. The tangential scratching force was usually smaller as compared to the normal scratching force, and the cross-sectional area of scratches in UVAS is smaller than that in CS. Based on the above findings, this study elucidates the formation and evolution of surface damage after scratching under different fiber orientations, filling the research gap in surface damage under ultrasonic assisted machining of Cf/SiC composites and providing technical guidance for the machining. 

Characterization, quantitative evaluation, and formation mechanism of surface damage in ultrasonic vibration assisted scratching of Cf/SiC composites

Abstract SiC particle reinforced Al matrix composites (SiC p /Al MMCs) have been widely used in aerospace and other fields due to their excellent mechanical properties, and their machined surface integrity is crucial for the use of new generation high-tech equipment. In order to enhance the understanding and regulation of machined surface integrity in Al matrix composites, this article provides a comprehensive review of the research advancements regarding influential factors, damage characteristics, creation techniques for machined surfaces, as well as technologies for controlling machined surface integrity both domestically and internationally. The present study discusses the key issues and solutions in the processing of aluminum matrix composite materials, along with examining the extent and mechanism of various energy field assistance influence on the surface integrity of mechanically processed aluminum matrix composites. Ultimately, this article proposes future research prospects for achieving high surface integrity machining of aluminum matrix composites. 

Machined surface formation and integrity control technology of SiCp/Al composites: a review

Nanosecond pulsed laser processing is an efficient method of processing carbon fiber reinforced plastic(CFRP), which is widely used in the manufacturing field of aviation, medical, and auto industries. The anisotropic heat transfer of carbon fiber is a key factor degrading the surface integrity of laser processing CFRP. So it is urgent to explore the significant mechanism of anisotropic heat transfer of laser interacting with CFRP. A novel numerical model considering anisotropic heat transfer was established to analyze heat transfer and thermal damage of CFRP laser machining. By comparison of simulation and experiments, the average error of ablation depth and width ranges from 4.71% to 15.09%, so the model could precisely simulate the CFRP laser machining. It demonstrates that the heat conductivity along the axial carbon fiber is higher than that along the radial, resulting in an elliptical ablation morphology. And when the laser scanning direction is parallel to the direction of the carbon fiber, deeper and narrower microgrooves can be obtained. In addition, laser processing at the edge of the CFRP plate causes serious heat accumulation, leading to severe thermal damage. The simulation and experiments were conducted to explore the effect of parameters including laser energy, scanning speed, and scanning space on the depth and width of laser ablation. A deeper micro-channel with a smooth machined surface and small thermal damage was obtained when laser energy E = 0.275 mJ, scanning speed v = 630 mm/s, and scanning space h = 21 μm. 

Study on anisotropic heat transfer and thermal damage in nanosecond pulsed laser processing of CFRP

Hole surface morphology and tool wear mechanisms during cutting 3D carbon/carbon composites using diamond core drill

Machining process is generally required for cutting composite material of structural components prior to final assembly in aerospace industry. This study aimed to investigate surface quality and mechanical behavior of open-hole composite laminates following different machining processes including abrasive waterjet cutting, high power fiber laser machining, conventional drilling and ultraviolet laser machining. Hole quality was quantified for further understanding the correlation between surface damage and mechanical behavior. Experimental results demonstrated that the hole geometrical accuracy and mechanical property were highly dependent on the machining methods. Digital image correlation technique was implemented to capture the strain distribution and strain evolution around open holes during tensile loading. Machining methods exhibited significant impact on ε yy $$ {\varepsilon}_{yy} $$ , ε xx , $$ {\varepsilon}_{xx}, $$ and ε xy $$ {\varepsilon}_{xy} $$ strain levels around hole edges, while limited influence on strain distribution patterns. ε yy $$ {\varepsilon}_{yy} $$ and ε xx $$ {\varepsilon}_{xx} $$ concentrated in the regions consisting of fibers perpendicular to and along the loading direction respectively, and shear strain ε xy $$ {\varepsilon}_{xy} $$ featured with X shape around hole edge. 

The influence of hole quality on mechanical behavior and strain distribution of open‐hole
 CFRP
 laminates subject to different machining processes

Grinding burn is an undesired defect in gear machining, and a white layer is an indication of severe burn that is detrimental to gear surface performance. In this work, the influence of grinding parameters on the thickness of the white layer during form grinding of quenched transmission gear was investigated, and the microstructure evolution and mechanism of severe burn formation were analyzed. The grinding temperature increased with the grinding depth and grinding speed, with the highest level of ~290 °C. The thickness of the white layer exceeded 100 μm when the grinding depth was 0.03 mm, and the top layer was a plastic deformation layer followed by a fine-grained martensite layer. Coarse-grained acicular martensite was found at the interface between the white layer and softened dark layer. The mechanical effect and thermal softening mainly contributed to the formation of white layer stratification. The ground surface topography showed several scratches and typical grooves; when grinding depth increased to 0.03 mm, the grinding surface roughness Sa was relatively high and reached up to ~0.60 μm, mainly owing to severe plastic deformation under grinding wheel extrusion and the thermal effect.

https://www.mdpi.com/1996-1944/15/21/7723/pdf?version=1667887341

Grinding Temperature and Surface Integrity of Quenched Automotive Transmission Gear during the Form Grinding Process

• The feasibility of high-power fiber laser cutting of thick SiCp/Al composite using single-pass strategy was investigated. • Surface morphology and cross-section characteristics were analyzed to understand material removal mechanisms. • Various thermal defects were qualified to study the influence of processing parameters on machining quality. • The formation mechanisms of different thermal damage during fiber laser cutting SiCp/Al composite were explained in details. Due to the introduction of ceramic reinforcement, the physical properties and machinability of SiCp/Al composites are greatly different from the metallic ones. High-power continuous wave fiber laser makes it possible to process SiCp/Al composites with high efficiency. In this work, the feasibility of high-power fiber laser cutting of 5.0 mm thick SiCp/Al composites was studied using design of experiments (DOE). The effects of laser power (1000–4000 W), cutting speed (500–2000 mm/min) and assist gas (N 2 and O 2 ) on kerf geometry and defect characterization were investigated. Results showed that high laser power and low cutting speed generated relatively higher kerf width on the entry surface, and the kerf width exhibited a slightly higher level around ∼ 2.0% when O 2 was applied in comparison to the results from N 2 group. Different morphology was observed on machined surfaces including multi-directional striation, vertical striation and slant striation. The width of HAZ increased along the direction of laser beam, and reached the maximum value at egress with the value up to 1115 μm. The SEM and EDX spectra study showed that the effect of oxygen on the subsurface was limited, and there was no metallurgical reaction between the matrix and SiC particles during laser cutting process. 

Surface morphology and defect characterization during high-power fiber laser cutting of SiC particles reinforced aluminum metal matrix composite

Surface Morphology and Kerf Quality During Fiber Laser Cutting of High Volume Fraction SiC Particles-Reinforced Aluminum Matrix Composites

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Hole surface morphology and tool wear mechanisms during cutting 3D carbon/carbon composites using diamond core drill

The influence of hole quality on mechanical behavior and strain distribution of open‐hole CFRP laminates subject to different machining processes

Grinding Temperature and Surface Integrity of Quenched Automotive Transmission Gear during the Form Grinding Process

Surface morphology and defect characterization during high-power fiber laser cutting of SiC particles reinforced aluminum metal matrix composite

Surface Morphology and Kerf Quality During Fiber Laser Cutting of High Volume Fraction SiC Particles-Reinforced Aluminum Matrix Composites