Prediction Model and Experimental Investigation of Elliptical Vibration Assisted Cutting Force for SiCp/Al Composite Materials

A cutting force prediction model for elliptical vibration-assisted cutting (EVC) cutting SiCp/Al composite materials was established. The flow stress of SiCp/Al was calculated based on the Johnson-Cook model, and the dynamic cutting force was decomposed into chip formation force, frictional force, ploughing force, and particle fracture force, according to the cutting characteristics at different stages of the EVC cycle were studied separately and decomposed along the cutting speed direction, depth of cut direction, and feed direction to obtain the prediction model for cutting forces in three directions. Orthogonal tests were designed to investigate the cutting parameters (cutting speed, depth of cut, and feed) by means of extreme difference analysis. The deviations between the experimental and predicted values of cutting forces in the three directions are compared through cutting experiments, and the reasons are analyzed to verify the validity of the established cutting force prediction model.