Three-dimensional finite element modelling research on single abrasive grit cutting for reaction-bonded silicon carbide ceramics

Abstract Reaction-bonded silicon carbide (RB-SiC) ceramics, characterized by high hardness, brittleness, and multiphase heterogeneity, exhibit severe surface/subsurface damage under dynamic machining loads. Due to the experimental cost constraints and the technical limitations in real-time monitoring of material removal mechanisms, this study addresses these challenges by developing a 3D single-abrasive-grit cutting finite element model (FEM) within ABAQUS/Explicit, integrating Voronoi tessellation and cohesive zone modelling (CZM) to approach RB-SiC’s heterogeneous microstructure. Scratch experiments validated the developed model’s accuracy in characterizing interfacial failure and material removal mechanisms. Subsequently, a preliminary investigation was conducted on the effect of cutting depth on cutting force for RB-SiC ceramics. This study offers foundational support for the future development of low-damage, high-quality machining strategies for RB-SiC ceramics, while simultaneously providing a referential framework for modelling and simulation of multiphase composite ceramics with analogous heterogeneous microstructures.