Research On Cutting Force Of SiCp/Al Composites By Elliptical Vibration Assisted Cutting

SiCp/Al composite has excellent mechanical and physical properties,but its machinability is poor,is a typical difficult to process materials,so the processing is very limited.Elliptical Vibration Assisted Cutting(EVC)is considered a promising technology.Elliptical Vibration assisted cutting(EVC)has the characteristics of intermittent cutting and reversal of friction force,which can effectively reduce cutting force,improve workpiece surface quality and extend tool life.It shows great superiority in processing difficult materials.However,the current research on EVC cutting SiCp/Al composite cutting force is not perfect,this paper aimed at EVC cutting SiCp/Al composite cutting force,in order to expect to provide a reference for EVC technology in the field of processing SiCp/Al composite applications,the main research content is as follows:(1)The cutting force prediction model of EVC cutting SiCp/Al composites was established.Considering the time-varying characteristics of EVC,a theoretical model of instantaneous cutting thickness and transient shear Angle was established.According to the characteristics of friction inversion of EVC,the cycle of EVC was divided into conventional cutting stage and friction inversion stage.The flow stress of SiCp/Al was calculated based on Johnson-Cook model.The dynamic cutting force was decomposed into chip forming force,friction force,ploughing force and particle fracture force.According to the cutting characteristics at different stages of EVC cycle,the cutting force prediction models in three directions were obtained by decomposition along cutting speed direction,cutting depth direction and feed direction.Orthogonal experiments were designed.The cutting parameters(cutting speed,cutting depth,feed)were studied by range analysis.(2)The two-dimensional finite element model of EVC cutting SiCp/Al composites was established.The polygonal particle random distribution model was established by using finite element analysis software and Python script,and different material properties were given to Si C particles,Al matrix and interface,respectively.The material removal mechanism and Mises stress distribution in the cutting process were analyzed,and the dynamic cutting force changes were analyzed compared with the traditional cutting.The effects of cutting parameters(cutting speed,cutting depth)and vibration parameters(phase difference,frequency,amplitude in X direction,amplitude in Y direction)on average main cutting force and average cutting resistance were studied.(3)Experimental research on cutting SiCp/Al composites by EVC was carried out.Turning experiments of SiCp/Al composites with 25% volume fraction were carried out on a NC machine tool using a non-resonant EVC device.Orthogonal experiments were set up according to the three factors of cutting speed,cutting depth and feed,and the deviations between the experimental values and the predicted values were compared and the reasons were analyzed to verify the effectiveness of the cutting force prediction model.The effect of vibration parameters(phase difference,frequency,amplitude in X direction and amplitude in Y direction)on cutting force was verified by single factor method.