Research on three-dimensional finite element modeling based on B₄C_p/Al meso-structure and cutting simulation

B₄C particle-reinforced Al matrix composite (B₄C_p/Al) has excellent properties and is expected to become the mainstream of composites in the future. Due to the complex meso-structure of B₄C_p/Al, this increases the difficulty of material precision machining. In addition, the current research on the PRMMCs generally focuses on SiC_p/Al and the effects of machining parameters on cutting force and temperature, while the research on the effects of tool geometry parameters on material cutting is relatively rare. Therefore, the cutting mechanism of B₄C_p/Al is studied by finite element simulation. Firstly, based on the meso-structure of B₄C_p/Al, a three-dimensional (3D) model of the material is established. Then the mechanism of surface formation of B₄C_p/Al was studied by combining cutting simulation and turning experiment. Use the simulation to study the effect of tool rake angle on material cutting surface quality. It was found that the removal mode of B₄C particles, the residual stress in Al matrix after cutting, and the plastic deformation would be affected by the tool rake angle, thus affecting the cutting surface quality. After a comprehensive comparison, it is found that when the rake angle is − 5°, the cutting quality is the best.