The experiment of PCD cutter and YG6X cutter milling SiCp/Al matrix composites was conducted, and the effect of tool material and machining parameters on cutting force and surface roughness was investigated, and the milling process of PCD tool was simulated with finite element software. The results showed that the axial thrust force was larger than the other two while precision milling 45% volume SiCp/Al matrix composites by YG6X tool, which resulting from great compressive strength of the material. The cutting force of PCD tool was much smaller than that of the YG6X, and the surface roughness of PCD tool was also smaller. Considering the cutting force and machining surface quality, YG6X should be used for rough machining, and PCD should be used for precision machining. The results of finite element simulation of PCD tools were in good agreement with experimental results, which can provide basis for production.
For the problems of machining distortion and the low accepted product during milling process of aluminum alloy thin-walled part,this paper starts from the analysis of initial stress state in material preparation process,the change process of residual stress within aluminum alloy pre-stretching plate is researched,and the distribution law of residual stress is indirectly obtained by delamination measurement methods,so the effect of internal residual stress on machining distortion is considered before finite element simulation. Considering the coupling effects of residual stress,dynamic milling force and clamping force on machining distortion,a threedimensional dynamic finite element simulation model is established,and the whole cutting process is simulated from the blank material to finished product,a novel prediction method is proposed,which can availably predict the machining distortion accurately. The machining distortion state of the thin-walled part is achieved at different processing steps,the machining distortion of the thin-walled part is detected with three coordinate measuring machine tools,show that the simulation results are in good agreement with experimental data.
