Enhanced machinability of aluminium-based silicon carbide by non-resonant vibration-assisted magnetorheological finishing

Aluminium-based silicon carbides (SiCp/Al) have been widely used due to their inherent unique physical and mechanical properties. However, improving the surface quality is challenging as finishing cannot meet the requirements of removing the height differences caused by the SiC and aluminium phases. This study aims to investigate the effectiveness of non-resonant vibration-assisted magnetorheological finishing (NVMRF) in reducing the referred height differences and then to enhance the surface quality. Finite element modeling (FEM) and molecular dynamics (MD) simulations were utilized to analyze the influence of the vibration on the fragmented particles as well as the reduction of two-phase height difference. Nano scratch experiments reveal the removal mechanism of the SiC phase in NVMRF. A material removal rate (MRR) model considering the influence of the exerted forces of abrasive particles and the concept of micro-removal mechanism was established. When analyzing the machining results, it was found that the plastic removal in the SiC phase contributed to the NVMRF. Besides, it was verified that the vibration-induced tangential force effectively reduced the height difference. Although there is a slight discrepancy between the theoretical and experimental values of the finishing force within the experimental parameters, the consistent trend confirms the effectiveness of the proposed method. Finally, this research provides a valuable method for finishing the particle-reinforced metal matrix composites (PRMMCs).