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<p>High volume fraction silicon carbide particle-reinforced aluminum matrix (SiC<sub>p</sub>/Al) composites are extensively applied in precision-critical industries because of superior physical and mechanical characteristics. The high volume fraction of SiC particles enhances the Al matrix performance and increases resistance during cutting, leading to higher cutting forces and random defects. Therefore, this paper used ultrasonic vibration-assisted grinding (UVAG) to enhance the machined quality of SiC<sub>p</sub>/Al composites and reduce machined damage. Specifically, the kinematic characteristics of the single diamond grain under ultrasonic vibration were analyzed. Combined with single grain grinding experiments and 3D simulation analysis, grinding forces, stress distribution, and surface/subsurface morphology were studied. The influence of the ultrasonic effect on material removal behavior and the extent of grinding-induced damage to SiC<sub>p</sub>/Al composites under various depths of cut <i>a</i><sub>p</sub> was clarified. The results show that UVAG reduces grinding forces, with normal and tangential forces decreasing by 26.9% and 37.2%, respectively, at the <i>a</i><sub>p</sub> of 20&#xa0;μm compared with CG. Ultrasonic vibration promotes the plastic removal and micro-crushing of the SiC, causing a 22.9% decrease in surface roughness <i>S</i><sub>a</sub> at <i>a</i><sub>p</sub> of 20&#xa0;μm. With the increasing <i>a</i><sub>p</sub>, SiC removal behavior transitions from plastic deformation to brittle fracture, deteriorating machined quality. As the <i>a</i><sub>p</sub> rises from 5&#xa0;μm to 20&#xa0;μm, the surface roughness <i>S</i><sub>a</sub> in UVAG increases from 0.39&#xa0;μm to 0.74&#xa0;μm, and subsurface damage depth increases from 5.4&#xa0;μm to 14.6&#xa0;μm. This study contributes to promoting the engineering application of UVAG in SiC<sub>p</sub>/Al composites and provides a theoretical basis for the high-quality machining of hard particle-reinforced metal matrix composites.</p>

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Study on ultrasonic vibration-assisted grinding characteristics of high volume fraction SiCp/Al composites

  • 期刊论文

  • 发表日期：

    2025年4月16日

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  • Xuebin Yao,
  • Wei Yu,
  • Jianhao Peng,
  • Wenfeng Ding,
  • Biao Zhao

摘要

High volume fraction silicon carbide particle-reinforced aluminum matrix (SiCp/Al) composites are extensively applied in precision-critical industries because of superior physical and mechanical characteristics. The high volume fraction of SiC particles enhances the Al matrix performance and increases resistance during cutting, leading to higher cutting forces and random defects. Therefore, this paper used ultrasonic vibration-assisted grinding (UVAG) to enhance the machined quality of SiCp/Al composites and reduce machined damage. Specifically, the kinematic characteristics of the single diamond grain under ultrasonic vibration were analyzed. Combined with single grain grinding experiments and 3D simulation analysis, grinding forces, stress distribution, and surface/subsurface morphology were studied. The influence of the ultrasonic effect on material removal behavior and the extent of grinding-induced damage to SiCp/Al composites under various depths of cut ap was clarified. The results show that UVAG reduces grinding forces, with normal and tangential forces decreasing by 26.9% and 37.2%, respectively, at the ap of 20 μm compared with CG. Ultrasonic vibration promotes the plastic removal and micro-crushing of the SiC, causing a 22.9% decrease in surface roughness Sa at ap of 20 μm. With the increasing ap, SiC removal behavior transitions from plastic deformation to brittle fracture, deteriorating machined quality. As the ap rises from 5 μm to 20 μm, the surface roughness Sa in UVAG increases from 0.39 μm to 0.74 μm, and subsurface damage depth increases from 5.4 μm to 14.6 μm. This study contributes to promoting the engineering application of UVAG in SiCp/Al composites and provides a theoretical basis for the high-quality machining of hard particle-reinforced metal matrix composites.