Comprehensive characterization of spark plasma sintered ZrB2-SiCp-SiCw composite and its corresponding orthogonal cutting simulation

Abstract

A composite consisting of 12.5 wt% SiC particles and 12.5 wt% SiC whiskers in a ZrB2 matrix (ZrB2-SiCp-SiCw) was produced using spark plasma sintering. The sintering process was carried out at a temperature of 1900 °C and a pressure of 40 MPa for a duration of 7 minutes. X-ray photoelectron spectroscopy analysis confirmed the presence of C-C, C-Si, O-B, O-Zr, O-Si, and Zr-B bonds. Scanning transmission electron microscopy and energy-dispersive X-ray spectroscopy analyses revealed the presence of silicon and carbon in the ZrB2 phase. The nano-indentation hardnesses and elastic moduli of ZrB2 and SiC were measured as 2104.58 and 2268.97 Vickers and 397.58 and 394.27 GPa, respectively, under a load of 100 mN and a loading rate of 0.4 mN/sec. The orthogonal cutting process of an Al6061 workpiece with a ZrB2-SiCp-SiCw cutting tool was simulated using DEFORM 2D software. The response surface method was used to develop a model to evaluate the relationship between cutting parameters (tool tip radius, cutting speed, and rake angle), cutting force, feeding force, and maximum temperature. It was found that cutting and feeding forces decrease with increasing cutting speed and rake angle, while increasing the tool tip radius increases these forces. The tool and workpiece endure a higher maximum temperature as the cutting speed and tool tip radius rise, but the maximum temperature drops as the rake angle increases. © 2024 Elsevier B.V.