Electric heat machining of SiCp/Al composites

SiC particles reinforced aluminum matrix (SiCp/Al) composites exhibit considerable potential for application in the aerospace and automobile manufacturing industries due to the characteristics of low density, high specific strength and high specific stiffness. However, machining of the composite material presents significant challenges owing to the presence of reinforced particles that result in complex friction at the tool-chip interface. This study presents the application of electric heat machining of 40 vol% SiCp/Al composites. A machining platform, equipped with a visual camera and an infrared imager, is employed to investigate the chip geometry, cutting forces, and cutting temperatures during the machining process. The findings indicate that electric heat machining offers the advantage of stabilizing cutting forces, with a corresponding reduction in cutting forces as electric power increase. Within a specific power range, a transition in chip geometry is observed, shifting from serrated to continuous, coinciding with a substantial decrease in cutting forces and a notable temperature rise within the shear zone. Furthermore, the results underscore the significant potential of electric heat machining for reducing cutting forces in the processing of SiCp/Al composites.