Numerical analysis of physical quantities during ultrasonic vibration assisted cutting of SiCp/Al composites

The turning process of SiCp/Al composites is challenging due to the inhomogeneity and complex interaction between different phases. Ultrasonic vibration-assisted cutting (UVAC) technology is one of the effective methods to improve the machinability of SiCp/Al composites, but it is still necessary to clarify the influence of ultrasonic impact effect on related physical quantities. In this paper, numerical methods and systematic cutting experiments are used to study the evolution of various physical quantities and their impact on machinability during UVAC for SiCp/Al composites. Firstly, the UVAC process is abstracted into an ultrasonic impact behavior, enabling the identification of impact parameters acting on the machined surface per unit time. Then, a 3D finite element model of equivalent homogeneous SiCp/Al composites is established to simulate the impact process. This model facilitates a comprehensive analysis of key parameters such as the process system energy, plastic deformation, stress distribution, and hydrostatic pressure. Finally, the evolution laws of physical quantities related to UVAC of SiCp/Al composites and their influence on surface quality are analyzed. The results show that the impact effect induced by UVAC changes the stress state of the machined surface and increases the average surface microhardness by 6.7%. Moreover, the presence of high compressive hydrostatic pressure in plastic deformation zone is conducive to densifying the subsurface and reducing the surface roughness by approximately 30%. These insights provide valuable theoretical guidance for the precision turning and surface treatment process of SiCp/Al composites.