Investigation on the micro-cutting mechanism of aluminum matrix composites with ultrasound elliptical vibration

This research explores how amplitude, vibration frequency, cutting depth, and aluminum content affect the micro-cutting of 7A09 aluminum composites with CoCrFeNiAl_X high-entropy alloy particle reinforcement. Through simulations, we compare conventional cutting (OC) to ultrasound elliptical vibration cutting (UEVC), assessing the mechanical behavior of the material. Findings show that UEVC generates higher temperatures than OC, but these can be mitigated by optimizing parameters, notably by reducing Y-axis amplitude from 90 to 30 μm, which lowers the temperature by 27%. Aluminum content is directly proportional to cutting temperature, with Al₀ content yielding a temperature roughly 95% that of Al₁.UEVC consistently results in lower cutting forces compared to OC, with the most significant reduction (32 occurring at X-axis 120 μm and Y-axis 30 μm amplitudes with a 25 kHz vibration frequency. Cutting forces increase with the aluminum content in the particles. Chip integrity is superior in OC, while UEVC predominantly produces ribbon-like chips. Stress in the chip layers is mostly concentrated in the primary deformation zone for Al₀ and Al₁ materials, whereas it is distributed more evenly in Al_0.6, with stress levels ranking from highest to lowest as Al₁, Al₀, and Al_0.6. This study illuminates the complex interactions between cutting conditions and material composition in high-entropy alloy particle-reinforced aluminum composites.