Influence of Micro-Textured Tools on Cutting Behavior in HEA-Reinforced Aluminum Matrix Composites
摘要
This study explores the effects of micro-textured tools on the high-speed cutting of CoCrFeNiAl0.6 (Al0.6) fiber-reinforced 7075 aluminum matrix composites. A simulation modeled the material removal of 90° unidirectional FRP, comparing conventional and micro-textured tools’ impacts on cutting forces, heat, and stress–strain relationships. Results show that during cutting, HEA fibers maintain plastic deformation without cracking under bending forces. The cutting force on fibers is significantly higher, especially on the third fiber, where the x-direction force increases to 1.3 times the average. At a 30 μm cutting depth, micro-textured tools reduce the cutting force by up to 23% compared to conventional tools. With increasing depth, only rectangular protrusion tools maintain lower cutting forces. Further analysis reveals that cutting forces with conventional tools increase with speed, reaching a 2.7 N difference at 70 m/min. At 60 m/min, conventional tools’ cutting temperature correlates positively with depth, while micro-textured tools show an initial increase, then decrease. Generally, conventional tools have lower temperatures, except at a 15 μm depth where rectangular protrusion tools significantly reduce temperatures by about 63 °C for the matrix and 34.3 °C for fibers. High-temperature zones for micro-textured tools are closer to the cutting edge, especially with protrusion textures. Stress distribution also varies by tool type. Conventional tools produce broader stress ranges but lower peaks, while rectangular textured tools prevent fiber pull-out. Micro-textured tools cause fractured fiber accumulation but have minimal impact on fiber strain. Near the machined surface, residual stress appears as compressive, with tensile stress in fibers away from the cut. Conventional tools cause frequent stress fluctuations with pronounced peaks, whereas micro-textured tools, especially protrusion textured ones, offer more stable stress, indicating better surface quality.