Finite Element Simulation Study of Ultrasonic-Assisted Vibration Cutting of Carbon Fiber Reinforced Polyetherketoneketone (CF/PEKK)

In the past few decades, the demand for carbon fiber reinforced polymer (CFRP) composites has significantly increased in aerospace, biomedical, and marine engineering industries due to their outstanding properties. These properties include high strength, high stiffness, low density, and excellent corrosion resistance. However, the high hardness and rigidity of polyetherketoneketone (CF/PEKK) materials result in high cutting forces during machining, which can lead to vibration and tool wear, posing significant challenges for numerical modeling, simulation, and process testing of the machining process. This study develops an ultrasonic vibration cutting force simulation model for carbon fiber reinforced CF/PEKK materials and validates the model’s effectiveness in predicting cutting forces and temperatures, with prediction errors controlled within 15%. The results provide a reliable theoretical basis for simulating the elliptical ultrasonic vibration cutting process of CF/PEKK materials and lay the foundation for future research in machining surface quality optimization and process improvement.