Abstract
To improve the processing quality and reduce the cost of SiCp/Al composites has become a key problem for its application. Rotary ultrasonic machining is highly suitable for machining of SiCp/Al composites with a medium or high volume fraction of reinforced phase, and the processing quality and efficiency could be improved greatly. In this article, the rotary ultrasonic machining experiments were performed for the SiCp/Al composites reinforced with 45% volume fraction, and the effects of processing parameters on the cutting force of face and flank machining were studied. The cutting force values reduce significantly, and the grinding force ratios Fn/ Ft of face and flank machining are 2.843 and 1.336, respectively, which indicate that better machinability can be achieved for SiCp/Al composites using rotary ultrasonic machining.
Highlights
SiCp/Al composites have many excellent mechanical and physical characteristics compared to its matrix material
The values of axial force Fz are much larger than the values of radial and feed forces, and it plays an important role in the material removal process of rotary ultrasonic machining (RUM)
The axial force Fz shows a downward trend with an increase in spindle speed and an upward trend with increases in feed rate and cutting depth
Summary
SiCp/Al composites have many excellent mechanical and physical characteristics compared to its matrix material. In RUM processing, a rotating hollow grinding wheel fitted with metal-bonded diamond abrasive grains vibrates with ultrasonic frequency in the axial direction and the feed movement is the same as milling, enabling high-quality and high-throughput processing of difficult-to-cut materials, such as ceramic, optical glass, and KDP (potassium dihydrogen phosphate) crystal.[7,8,9] The removal rate of RUM is far more than that of conventional grinding under the same condition; machining speed is high and tool wear is low.[10,11,12]. All of the aforementioned factors could enhance the material removal rate, lower the cutting force, and improve the surface quality
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