Finite element analysis and experimental study on the cutting mechanism of SiCp/Al composites by ultrasonic vibration-assisted cutting

SiCp/Al composites are considered difficult to machine due to the relatively high hardness of SiC particles. In this paper, ultrasonic vibration-assisted cutting (UVAC) technology is used to improve the machining of SiCp/Al composites. Firstly, cutting process of conventional cutting (CC) and UVAC of SiCp/Al composites are simulated by the finite element simulation method. Moreover, damage characteristics of SiC particles are explored when tool cutting path is located at different positions of SiC particles within the two machining methods. Machined surface/subsurface damage of workpiece is observed, and consistency with simulation results is verified. Then, combined with energy dispersive spectroscopy analysis technology, tool wear mechanism of UVAC and CC is explored, and wear characteristics of tool flank are analyzed. Moreover, chip formation features of UVAC and CC are also compared. Finally, relationship between the cutting force and surface roughness during CC and UVAC regarding different cutting process parameters is compared. According to obtained results, UVAC technology could reduce tool wear, improve machinability of SiCp/Al composites, and improve surface integrity of SiCp/Al composites, where cutting force is reduced by about 40%, surface roughness is reduced by 34%, and subsurface damage depth is reduced by 86%.