The Experimental Study Of High Volume Fraction SiCp/Al Composites With Ultrasonic High-speed Milling

Silicon carbide particles reinforced aluminum matrix composites (SiCp/Al) is a new composite materials, with superior performance of high strength, high elastic modulus, high temperature resistant etc, and the application prospect in the fields of the aerospace, automotive manufacturing and other areas are very well. With the high hardness of the reinforcement SiC content increasing, processing is very difficult, and seriously hindered the development of the material. In order to solve the difficult-to-machine problems of high volume content SiCp/Al composite, the paper introduced ultrasound longitudinal high frequency vibration, hoping to reduce ordinary milling harmful effects of vibration machining quality, and reduce the tool wear, reduce milling force and improve milling quality, enlarge the scope of ultrasonic machining.In this paper, ultrasonic high frequency longitudinal vibration milling of high volume fraction SiCp/Al composite is studied. The theoretical model of ultrasonic vibration cutting force is established; using the self-made ultrasonic milling system in the process, this paper studied the change rule of cutting force and each milling parameters, finally, analyzed workpiece surface microstructure under ultrasonic milling by metalloscope and electron microscopy, established two-dimensional and three-dimensional surface morphology model of ultrasonic longitudinal vibration milling .This paper studied material removal process of more than 60 percent SiC in the SiCp/Al composite, studied the influence of various milling parameters on the machined surface roughness with the white light interferometer, and studied the tool wear shape with the tool microscope, analyzed the causes of the tool wear.The results show that: under the same cutting parameters, vibration milling force is lower than common milling, the chip of ultrasonic longitudinal vibration milling got sawed chips, ordinary milling got broken chips; the tools wear quantity under ultrasonic vibration was far less than normal milling; the tool wear was mainly flank wear, the tool wear reasons are hard spots wear and thermal and chemical wear; PCD cutting tool is the optimal cutting tools when processing SiCp/Al composites.