Research On Surface Defect Formation And Suppression In Ultrasonic Vibration Milling And Grinding Of SiCp/Al Composites

Si Cp/Al composites have broad application prospects due to their high strength,stiffness,thermal conductivity,and elastic modulus,as well as excellent dimensional stability,heat resistance,and high temperature resistance.The low plasticity and high hardness silicon carbide particles improve the performance of the material,but also reduce the workability of the Si Cp/Al composite material,making it a typical difficult-to-process material.It is of great theoretical significance and practical value to study the formation and suppression methods of the processed surface defects of this kind of material for improving the quality of the processed surface.In order to study the mechanism of surface damage in ultrasonic vibration milling of Si Cp/Al composites,a micro-multiphase material model of Si Cp/Al composites was established in this paper.Using Matlab software,the microstructure inspection photos of Si Cp/Al composites were processed with relevant images,and the particle shape,size and position distribution information were image identified and extracted;the average of Si C particles in the microstructure of Si Cp/Al material was carried out The statistical analysis of the size and shape obtained the parameters of Si C particle size,shape and position distribution;the kinematic analysis of the ultrasonic cutting of the single abrasive particle of the milling tool was carried out,and the combined effect of the abrasive particle in the ultrasonic vibration processing and the milling processing was obtained On the basis of this,the trajectory of the movement is combined with the Python language to write a program,and the finite element simulation model is established through the ABAQUS finite element simulation software.In order to study the formation of ultrasonic milling surface defects and influencing factors,an ultrasonic rotary scribing experiment was designed,and the microscopic appearance of the surface after scribing was observed.Based on the ultrasonic micro-cutting model,the surface defect characteristics of the tool when cutting different parts of the particle were analyzed,and the effect of the different contact positions of the single abrasive particle of the tool and the Si C particle on the formation of surface defect was studied.Relevant analysis and verification of the defect form of sticking out.On the basis of the above research,the suppression of surface defects in Si Cp/Al composites processed by ultrasonic vibration milling was studied,and the parameter constraints based on material removal characteristics were analyzed,mainly for Al matrix and Si C particles.analysis.Constrain the parameters from three aspects,including particle material removal,matrix material removal,and the effect of ultrasonic vibration on material removal.The defect suppression constraint equation and optimization model were established respectively,the processing parameters were optimized,and the optimization results were experimentally verified.