ZHANG M J, CHEN S, WANG X B,et al.Study on the surface quality of SiCp/Al composite materials by longitudinal-torsional ultrasonic assisted milling[J].Journal of Henan Polytechnic University(Natural Science) ,2024,43(5):96-107.

doi:10.16186/j.cnki.1673-9787.2024030047

Received:2024/03/17

Revised:2024/04/30

Published:2024/07/31

Study on the surface quality of SiCp/Al composite materials by longitudinal-torsional ultrasonic assisted milling

ZHANG Mingjun, CHEN Shuo, WANG Xinbo, YANG Jiangtao, LIU Helong, LYU Yaowei, LI Dehui, YU Mingbo

School of Mechanical and Power Engineering， Henan Polytechnic University， Jiaozuo 454000， Henan， China

Abstract:High volume fraction SiCp/Al composites have excellent properties such as high specific strength，high specific modulus and good wear resistance.However，their high hardness and brittleness can lead to complex stress distributions in the precision manufacturing process，which can lead to excessive force and heat and thus affect the accuracy and durability limits. Objectives By analyzing the removal of particles and the types of surface defects in the cutting process，the longitudinal-torsional ultrasonic assisted milling （LTUAM） technology was used to improve the surface quality of high volume fraction SiCp/Al composites.  Methods ABAQUS and PYTHON software were used to establish a model of two-phase randomly distributed SiCp/Al composites considering the fracture process of particles.The Johnson-Cook model and the Brittle Cracking model were used to simulate the longitudinal-torsional ultrasonic assisted milling process of SiCp/Al composites using finite element method.For different machining parameters，the longitudinal-torsional ultrasonic assisted milling and conventional milling （CM） tests of SiCp/Al composites were carried out to evaluate the consistency between the finite element simulation and the test results.  Results The simulation results showed that the damage and cracks mainly occurred on the cutting line in the middle and upper part of SiC particles，and the pitting defects mainly occured on the cutting line in the lower part of SiC particles.The test results showed that the types of surface defects mainly included particle damage and pulling out，particle damage and fracture forming pits，undamaged particles forming bumps，damaged particles and tools forming furrows on the machined surface by extrusion friction，aluminum matrix coating，surface micro-cracks and surface holes，and so on.Moreover，when the processing speed was 120 m/min and ultrasonic amplitude was 3 μm，the maximum crack depth was the smallest， the surface defect was the smallest and the surface quality was the best. Conclusions Comparing the finite element simulation results with the experimental results，it was found that the surface quality change trend of the two was basically consistent. The application of longitudinal-torsional ultrasonic assisted milling technology had a good effect on improving the surface quality of SiCp/Al composites.

Key words:SiCp/Al composite material;finite element simulation;ultrasonic machining;surface quality;hard and brittle material