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<p>This study addresses surface quality degradation in machining silicon carbide-reinforced aluminum matrix (SiCp/Al) composite thin-walled parts, induced by deformation from insufficient stiffness. A three-dimensional representative volume element (RVE) model, reflecting the composite’s true microstructure, was established via Abaqus. Using multi-scale finite element method (FEM) based on sub-modeling technique, macroscopic damage was linked to microscopic failure mechanisms, elucidating the deformation/fracture behaviors of constituent phases. Meanwhile, stress distribution and evolution at 30 typical milling positions (across three thickness layers: surface/subsurface substrate surface, and three height layers: bottom/middle/top) were analyzed to clarify material removal mechanisms. The effect of a Fortran-encoded VDLOAD movable auxiliary support on damage evolution was specifically examined. Results show that the auxiliary support significantly mitigates local high stress and surface damage. Stress distribution is notably position-sensitive, with top and bottom surfaces exhibiting more severe damage. Moreover, particle fracture and debonding accelerate crack propagation, worsening surface quality. This work provides a key theoretical foundation for position-dependent damage prediction, deformation control, and surface quality improvement in SiCp/Al composite thin-walled parts machining.</p>

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Multi-Scale Modeling-Simulation of Positional Damage in Milling SiCp/Al Composite Thin-Walled Parts With Movable Auxiliary Support

  • 期刊论文

  • 发表日期：

    2026年3月9日

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  • Aoqi Liu,
  • Shutong Liu,
  • Zhijie Gao,
  • Li Zhou

摘要

This study addresses surface quality degradation in machining silicon carbide-reinforced aluminum matrix (SiCp/Al) composite thin-walled parts, induced by deformation from insufficient stiffness. A three-dimensional representative volume element (RVE) model, reflecting the composite’s true microstructure, was established via Abaqus. Using multi-scale finite element method (FEM) based on sub-modeling technique, macroscopic damage was linked to microscopic failure mechanisms, elucidating the deformation/fracture behaviors of constituent phases. Meanwhile, stress distribution and evolution at 30 typical milling positions (across three thickness layers: surface/subsurface substrate surface, and three height layers: bottom/middle/top) were analyzed to clarify material removal mechanisms. The effect of a Fortran-encoded VDLOAD movable auxiliary support on damage evolution was specifically examined. Results show that the auxiliary support significantly mitigates local high stress and surface damage. Stress distribution is notably position-sensitive, with top and bottom surfaces exhibiting more severe damage. Moreover, particle fracture and debonding accelerate crack propagation, worsening surface quality. This work provides a key theoretical foundation for position-dependent damage prediction, deformation control, and surface quality improvement in SiCp/Al composite thin-walled parts machining.