Hypereutectic aluminium-silicon (Al-Si) alloys are used in automobile
components because of high wear resistance and good
strength properties. In this study, the cutting of a hypereutectic
Al-Si alloy with a single-crystal diamond tool for economical
production was investigated by simulation. Tool life and the
extraction rate of Si particles are inversely proportional to the
depth of cut. By reducing the depth of cut, reductions of tool
cost and tool changing time are achieved.