Experimental Study on High-Speed Milling of SiCf/SiC Composites with PCD and CVD Diamond Tools
Silicon carbide fiber reinforced silicon carbide ceramic matrix composite (SiC<sub>f</sub>/SiC composite) is characterized by a high strength-to-density ratio, high hardness, and high temperature resistance. However, due to the brittleness of the matrix material and the anisotropy of the...
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MDPI AG
2021-06-01
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| Online Access: | https://www.mdpi.com/1996-1944/14/13/3470 |
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| author | Bin Zhang Yanan Du Hanliang Liu Lianjia Xin Yinfei Yang Liang Li |
| author_facet | Bin Zhang Yanan Du Hanliang Liu Lianjia Xin Yinfei Yang Liang Li |
| author_sort | Bin Zhang |
| collection | DOAJ |
| description | Silicon carbide fiber reinforced silicon carbide ceramic matrix composite (SiC<sub>f</sub>/SiC composite) is characterized by a high strength-to-density ratio, high hardness, and high temperature resistance. However, due to the brittleness of the matrix material and the anisotropy of the reinforcing phase, it is a huge challenge for machining of the material. The milling method has advantages of a high material removal rate and applicability to complex surface geometry. However, no published literature on milling of SiC<sub>f</sub>/SiC composite has been found up to now. In this paper, high-speed milling of SiC<sub>f</sub>/SiC composites was carried out under dry conditions and cryogenic cooling using liquid nitrogen, respectively. Polycrystalline diamond (PCD) and chemical vapor deposition (CVD) diamond cutting tools were used for the milling work. The cutting performance of the two kinds of tools in high-speed milling of SiC<sub>f</sub>/SiC composites was studied. Tool failure modes and mechanisms were analyzed. The effects of the cooling approach on tool wear and machined surface quality were also investigated. The experimental results showed that under identical cutting parameters and cooling approaches, the PCD tool yielded better cutting performance in terms of a longer tool life and better surface quality than that of the CVD diamond tool. In dry machining, the failure modes of the CVD diamond tool were a large area of spalling on the rake face, edge chipping and severe tool nose fracture, whereas for the PCD tool, only a small area of spalling around the tool nose took place. Compared to the dry machining, the wear magnitudes of both PCD and CVD diamond tools were decreased in cryogenic machining. Additionally, the surface quality also showed significant improvements. This study indicates that the PCD tool is highly suitable for machining of SiC<sub>f</sub>/SiC composite, and that the cryogenic method can improve machining efficiency and surface quality. |
| first_indexed | 2024-03-10T10:10:26Z |
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| institution | Directory Open Access Journal |
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| language | English |
| last_indexed | 2024-03-10T10:10:26Z |
| publishDate | 2021-06-01 |
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| series | Materials |
| spelling | doaj.art-27f7dde32c3c49caa0f30501837fcdc42023-11-22T01:13:02ZengMDPI AGMaterials1996-19442021-06-011413347010.3390/ma14133470Experimental Study on High-Speed Milling of SiCf/SiC Composites with PCD and CVD Diamond ToolsBin Zhang0Yanan Du1Hanliang Liu2Lianjia Xin3Yinfei Yang4Liang Li5Beijing Spacecrafts, Beijing 100094, ChinaCollege of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, ChinaBeijing Spacecrafts, Beijing 100094, ChinaCollege of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, ChinaCollege of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, ChinaCollege of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, ChinaSilicon carbide fiber reinforced silicon carbide ceramic matrix composite (SiC<sub>f</sub>/SiC composite) is characterized by a high strength-to-density ratio, high hardness, and high temperature resistance. However, due to the brittleness of the matrix material and the anisotropy of the reinforcing phase, it is a huge challenge for machining of the material. The milling method has advantages of a high material removal rate and applicability to complex surface geometry. However, no published literature on milling of SiC<sub>f</sub>/SiC composite has been found up to now. In this paper, high-speed milling of SiC<sub>f</sub>/SiC composites was carried out under dry conditions and cryogenic cooling using liquid nitrogen, respectively. Polycrystalline diamond (PCD) and chemical vapor deposition (CVD) diamond cutting tools were used for the milling work. The cutting performance of the two kinds of tools in high-speed milling of SiC<sub>f</sub>/SiC composites was studied. Tool failure modes and mechanisms were analyzed. The effects of the cooling approach on tool wear and machined surface quality were also investigated. The experimental results showed that under identical cutting parameters and cooling approaches, the PCD tool yielded better cutting performance in terms of a longer tool life and better surface quality than that of the CVD diamond tool. In dry machining, the failure modes of the CVD diamond tool were a large area of spalling on the rake face, edge chipping and severe tool nose fracture, whereas for the PCD tool, only a small area of spalling around the tool nose took place. Compared to the dry machining, the wear magnitudes of both PCD and CVD diamond tools were decreased in cryogenic machining. Additionally, the surface quality also showed significant improvements. This study indicates that the PCD tool is highly suitable for machining of SiC<sub>f</sub>/SiC composite, and that the cryogenic method can improve machining efficiency and surface quality.https://www.mdpi.com/1996-1944/14/13/3470SiC<sub>f</sub>/SiC compositecryogenic machiningPCD toolCVD diamond tooltool wear |
| spellingShingle | Bin Zhang Yanan Du Hanliang Liu Lianjia Xin Yinfei Yang Liang Li Experimental Study on High-Speed Milling of SiCf/SiC Composites with PCD and CVD Diamond Tools Materials SiC<sub>f</sub>/SiC composite cryogenic machining PCD tool CVD diamond tool tool wear |
| title | Experimental Study on High-Speed Milling of SiCf/SiC Composites with PCD and CVD Diamond Tools |
| title_full | Experimental Study on High-Speed Milling of SiCf/SiC Composites with PCD and CVD Diamond Tools |
| title_fullStr | Experimental Study on High-Speed Milling of SiCf/SiC Composites with PCD and CVD Diamond Tools |
| title_full_unstemmed | Experimental Study on High-Speed Milling of SiCf/SiC Composites with PCD and CVD Diamond Tools |
| title_short | Experimental Study on High-Speed Milling of SiCf/SiC Composites with PCD and CVD Diamond Tools |
| title_sort | experimental study on high speed milling of sicf sic composites with pcd and cvd diamond tools |
| topic | SiC<sub>f</sub>/SiC composite cryogenic machining PCD tool CVD diamond tool tool wear |
| url | https://www.mdpi.com/1996-1944/14/13/3470 |
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