Machining-induced damage in milling of Cf/SiC composites: mechanisms and evaluation methods

IF 8.1 2区材料科学 Q1 ENGINEERING, MANUFACTURING

Composites Part A: Applied Science and Manufacturing Pub Date : 2025-10-05 DOI:10.1016/j.compositesa.2025.109322

Zhiwen Nian, Guolong Zhao, Li Zhu, Haotian Yang, Liang Li

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引用次数: 0

Abstract

Carbon fiber-reinforced silicon carbide (C_f/SiC) composites have been widely utilized in the aerospace industry due to their high specific strength and ablation resistance. However, owing to their high hardness, brittleness, and anisotropy, machining-induced damages are prone to occur. In this study, the formation mechanisms of milling-induced damage in C_f/SiC composites were investigated. The results demonstrated that pit damage, as the most prominent form of milling-induced damage, exhibits three primary formation mechanisms: crushing damage caused by axial machining loads compressing subsurface inherent defects, extrusion cracking damage resulting from radial-load-induced crack propagation along fiber bundles, and fragment spalling damage occurring when the tool’s compressive and scraping actions on fragments within inherent defects cause damage expansion. A novel damage evaluation model for milling C_f/SiC composites was established by weighting the maximum damage depth with the ratio of newly generated damage area to the total machined area. A response prediction model for the damage index was developed with respect to three parameters: cutting speed, feed pre tooth, and radial depth of cut. Verification tests conducted with the optimized parameters yielded results with a deviation of 2.26% from the predicted model, confirming the reliability of the prediction model.

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Cf/SiC复合材料铣削加工损伤机理及评价方法

碳纤维增强碳化硅（Cf/SiC）复合材料具有高比强度和抗烧蚀性能，在航空航天领域得到了广泛的应用。然而，由于其高硬度、脆性和各向异性，容易发生加工损伤。研究了Cf/SiC复合材料铣削损伤的形成机制。结果表明，坑损伤是铣削诱发损伤中最突出的一种形式，其主要形成机制有三种：轴向加工载荷压缩亚表面固有缺陷导致的破碎损伤，径向载荷诱导的纤维束裂纹扩展导致的挤压开裂损伤，刀具对固有缺陷内碎片的压缩和刮擦作用导致损伤扩展导致的碎片剥落损伤。通过将最大损伤深度与新生成损伤面积占总加工面积之比加权，建立了一种新的铣削Cf/SiC复合材料损伤评价模型。建立了基于切削速度、进给预齿和径向切削深度三个参数的损伤指标响应预测模型。利用优化后的参数进行验证试验，结果与预测模型偏差为2.26%，验证了预测模型的可靠性。

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来源期刊

Composites Part A: Applied Science and Manufacturing 工程技术-材料科学：复合

CiteScore

15.20

自引率

5.70%

发文量

492

审稿时长

30 days

期刊介绍： Composites Part A: Applied Science and Manufacturing is a comprehensive journal that publishes original research papers, review articles, case studies, short communications, and letters covering various aspects of composite materials science and technology. This includes fibrous and particulate reinforcements in polymeric, metallic, and ceramic matrices, as well as 'natural' composites like wood and biological materials. The journal addresses topics such as properties, design, and manufacture of reinforcing fibers and particles, novel architectures and concepts, multifunctional composites, advancements in fabrication and processing, manufacturing science, process modeling, experimental mechanics, microstructural characterization, interfaces, prediction and measurement of mechanical, physical, and chemical behavior, and performance in service. Additionally, articles on economic and commercial aspects, design, and case studies are welcomed. All submissions undergo rigorous peer review to ensure they contribute significantly and innovatively, maintaining high standards for content and presentation. The editorial team aims to expedite the review process for prompt publication.