Removal mechanism and damage evolution of SiCp/Al composites based on FEM-MD model considering 3D random polyhedral particles in orthogonal cutting
This study investigates the cutting mechanism and particle damage evolution of SiCp/Al composites using a coupled FEM-MD modeling approach. A Python-based algorithm was developed for generating representative volume element (RVE) through stochastic convex polyhedron modeling, enabling geometrically...
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| Language: | English |
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Elsevier
2025-05-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785425007628 |
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| author | Ming Li Qingguang Li Xianchao Pan Jiaqi Wang Zixuan Wang Shengzhi Xu Yunguang Zhou Lianjie Ma Tianbiao Yu |
| author_facet | Ming Li Qingguang Li Xianchao Pan Jiaqi Wang Zixuan Wang Shengzhi Xu Yunguang Zhou Lianjie Ma Tianbiao Yu |
| author_sort | Ming Li |
| collection | DOAJ |
| description | This study investigates the cutting mechanism and particle damage evolution of SiCp/Al composites using a coupled FEM-MD modeling approach. A Python-based algorithm was developed for generating representative volume element (RVE) through stochastic convex polyhedron modeling, enabling geometrically faithful reconstruction of particle morphologies. At the micro-scale, molecular dynamics simulations calibrated the cohesive zone model parameters for Al–SiC interface, while meso-scale finite element modeling incorporated these MD-derived interfacial properties to establish particle-matrix interaction dynamics. Orthogonal cutting simulations systematically revealed three speed-dependent material removal regimes: 1) Low-speed (<200 mm/s) particle extraction inducing matrix tearing through interfacial debonding; 2) Medium-speed (200–400 mm/s) extrusion-dominated fragmentation generating angular debris; 3) High-speed (>400 mm/s) impact-induced comminution producing refined fragments that minimize surface damage. The polyhedral particle model demonstrated superior predictive accuracy over spherical approximations, particularly in capturing edge-driven stress concentrations and anisotropic debonding patterns. Experimental validation confirmed the multi-scale model's predictive accuracy for machining-induced surface damage. This study extends multi-scale modeling methodologies for composite machining by uniquely integrating Python-based stochastic geometry reconstruction with MD-calibrated interfacial mechanics, providing a systematic framework for studying the damage mechanism of SiCp/Al composites machining. |
| format | Article |
| id | doaj-art-95e05f8080e04cd8a8cd58090663dc4f |
| institution | OA Journals |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-95e05f8080e04cd8a8cd58090663dc4f2025-08-20T01:55:11ZengElsevierJournal of Materials Research and Technology2238-78542025-05-01362127214510.1016/j.jmrt.2025.03.251Removal mechanism and damage evolution of SiCp/Al composites based on FEM-MD model considering 3D random polyhedral particles in orthogonal cuttingMing Li0Qingguang Li1Xianchao Pan2Jiaqi Wang3Zixuan Wang4Shengzhi Xu5Yunguang Zhou6Lianjie Ma7Tianbiao Yu8School of Mechanical Engineering and Automation, Northeastern University, Shenyang, 110819, China; School of Control Engineering, Northeastern University at Qinhuangdao, Qinhuangdao, 066004, China; Liaoning Provincial Key Laboratory of Intelligent Design and Manufacturing Technology for Large Equipment, Northeastern University, Shenyang, 110819, China; Corresponding author. School of Mechanical Engineering and Automation, Northeastern University, Shenyang, 110819, China.School of Mechanical Engineering and Automation, Northeastern University, Shenyang, 110819, China; School of Control Engineering, Northeastern University at Qinhuangdao, Qinhuangdao, 066004, ChinaSchool of Mechanical Engineering and Automation, Northeastern University, Shenyang, 110819, China; School of Control Engineering, Northeastern University at Qinhuangdao, Qinhuangdao, 066004, ChinaSchool of Mechanical Engineering and Automation, Northeastern University, Shenyang, 110819, China; School of Control Engineering, Northeastern University at Qinhuangdao, Qinhuangdao, 066004, ChinaSchool of Mechanical Engineering and Automation, Northeastern University, Shenyang, 110819, China; Liaoning Provincial Key Laboratory of Intelligent Design and Manufacturing Technology for Large Equipment, Northeastern University, Shenyang, 110819, China; Corresponding author. School of Mechanical Engineering and Automation, Northeastern University, Shenyang, 110819, China.Department of Unmanned Aerial Vehicle Engineering, Shijiazhuang Campus of Army Engineering University, Shijiazhuang, 050003, China; Corresponding author.School of Mechanical Engineering and Automation, Northeastern University, Shenyang, 110819, China; School of Control Engineering, Northeastern University at Qinhuangdao, Qinhuangdao, 066004, ChinaSchool of Mechanical Engineering and Automation, Northeastern University, Shenyang, 110819, China; School of Control Engineering, Northeastern University at Qinhuangdao, Qinhuangdao, 066004, ChinaSchool of Mechanical Engineering and Automation, Northeastern University, Shenyang, 110819, China; Liaoning Provincial Key Laboratory of Intelligent Design and Manufacturing Technology for Large Equipment, Northeastern University, Shenyang, 110819, ChinaThis study investigates the cutting mechanism and particle damage evolution of SiCp/Al composites using a coupled FEM-MD modeling approach. A Python-based algorithm was developed for generating representative volume element (RVE) through stochastic convex polyhedron modeling, enabling geometrically faithful reconstruction of particle morphologies. At the micro-scale, molecular dynamics simulations calibrated the cohesive zone model parameters for Al–SiC interface, while meso-scale finite element modeling incorporated these MD-derived interfacial properties to establish particle-matrix interaction dynamics. Orthogonal cutting simulations systematically revealed three speed-dependent material removal regimes: 1) Low-speed (<200 mm/s) particle extraction inducing matrix tearing through interfacial debonding; 2) Medium-speed (200–400 mm/s) extrusion-dominated fragmentation generating angular debris; 3) High-speed (>400 mm/s) impact-induced comminution producing refined fragments that minimize surface damage. The polyhedral particle model demonstrated superior predictive accuracy over spherical approximations, particularly in capturing edge-driven stress concentrations and anisotropic debonding patterns. Experimental validation confirmed the multi-scale model's predictive accuracy for machining-induced surface damage. This study extends multi-scale modeling methodologies for composite machining by uniquely integrating Python-based stochastic geometry reconstruction with MD-calibrated interfacial mechanics, providing a systematic framework for studying the damage mechanism of SiCp/Al composites machining.http://www.sciencedirect.com/science/article/pii/S2238785425007628SiCp/Al compositesRemoval mechanismDamage evolutionFEM-MD model3D random polyhedral particles |
| spellingShingle | Ming Li Qingguang Li Xianchao Pan Jiaqi Wang Zixuan Wang Shengzhi Xu Yunguang Zhou Lianjie Ma Tianbiao Yu Removal mechanism and damage evolution of SiCp/Al composites based on FEM-MD model considering 3D random polyhedral particles in orthogonal cutting Journal of Materials Research and Technology SiCp/Al composites Removal mechanism Damage evolution FEM-MD model 3D random polyhedral particles |
| title | Removal mechanism and damage evolution of SiCp/Al composites based on FEM-MD model considering 3D random polyhedral particles in orthogonal cutting |
| title_full | Removal mechanism and damage evolution of SiCp/Al composites based on FEM-MD model considering 3D random polyhedral particles in orthogonal cutting |
| title_fullStr | Removal mechanism and damage evolution of SiCp/Al composites based on FEM-MD model considering 3D random polyhedral particles in orthogonal cutting |
| title_full_unstemmed | Removal mechanism and damage evolution of SiCp/Al composites based on FEM-MD model considering 3D random polyhedral particles in orthogonal cutting |
| title_short | Removal mechanism and damage evolution of SiCp/Al composites based on FEM-MD model considering 3D random polyhedral particles in orthogonal cutting |
| title_sort | removal mechanism and damage evolution of sicp al composites based on fem md model considering 3d random polyhedral particles in orthogonal cutting |
| topic | SiCp/Al composites Removal mechanism Damage evolution FEM-MD model 3D random polyhedral particles |
| url | http://www.sciencedirect.com/science/article/pii/S2238785425007628 |
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