Kannan Sathish, Pervaiz Salman, Alhourani Abdulla, Klassen Robert J, Selvam Rajiv, Haghshenas Meysam
Department of Mechanical Engineering, American University of Sharjah, Sharjah 26666, UAE.
Department of Mechanical and Industrial Engineering, Rochester Institute of Technology-Dubai Campus, Dubai 341055, UAE.
Materials (Basel). 2020 Aug 11;13(16):3534. doi: 10.3390/ma13163534.
The role played by hollow ceramic thin-walled aluminium oxide microballoons on the shear deformation characteristics of AZ31 Magnesium syntactic foam is studied through high-speed machining. The ceramic microballoons embedded in the AZ31 matrix provides the necessary stiffness for these novel foams. The effect of hollow ceramic microballoon properties, such as the volume fraction, thin wall thickness to diameter ratio, and microballoon diameter, profoundly affects the chip formation. A novel force model has been proposed to explain the causes of variation in cutting forces during chip formation. The results showed an increase in machining forces during cutting AZ31 foams dispersed with higher volume fraction and finer microballoons. At a lower (Davg/h) ratio, the mode of microballoon deformation was a combination of bubble burst and fracture through an effective load transfer mechanism with the plastic AZ31 Mg matrix. The developed force model explained the key role played by AZ31 matrix/alumina microballoon on tool surface friction and showed a better agreement with measured machining forces.
通过高速加工研究了空心陶瓷薄壁氧化铝微球对AZ31镁基复合泡沫材料剪切变形特性的作用。嵌入AZ31基体中的陶瓷微球为这些新型泡沫材料提供了必要的刚度。空心陶瓷微球的性能，如体积分数、薄壁厚度与直径比以及微球直径，对切屑形成有深远影响。提出了一种新颖的力模型来解释切屑形成过程中切削力变化的原因。结果表明，切削含有较高体积分数和更细微球的AZ31泡沫材料时，加工力会增加。在较低的（Davg/h）比下，微球变形模式是通过与塑性AZ31镁基体的有效载荷传递机制实现气泡破裂和断裂的组合。所建立的力模型解释了AZ31基体/氧化铝微球在刀具表面摩擦中所起的关键作用，并与实测加工力表现出更好的一致性。
