Mg2Si/Al composites are widely used in aerospace and automotive lightweight applications due to their excellent structural properties, such as superior specific stiffness, specific strength, and wear resistance. The removal mechanism of Mg2Si/Al composites is explored by establishing a finite element milling simulation model. A three-factor, four-level milling experiment based on the orthogonal experimental method is conducted to illustrate the patterns of the effects of milling parameters and surface defects on surface quality. Suitable milling parameters are successfully optimized by predictive modeling and experimental validation methods. The results show that the removal of Mg2Si/Al composites is mainly characterized by plastic deformation of the aluminum matrix and brittle fracture, crushing, bulging, and pulling out of Mg2Si particles.
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