Modeling of the Longitudinal Torsional Ultrasonic Vibration-Assisted Milling of UD-CF/PPS Composites Through Capturing the Influences of Both the Longitudinal and the Torsional Vibrations

Owing to its infinite shelf-life under ambient conditions, satisfactory recyclability, and great reparability, carbon fiber-reinforced polyphenylene sulfide (CF/PPS) has been increasingly applied in the near-net-shape manufacture of high-value components. Longitudinal torsional ultrasonic vibration-assisted milling (LTUVAM) shows strong potential as an advanced processing technology for the efficient precision machining of composites. However, studies and models on the explanation of LTUVAM of CF/PPS composites seem to be missing in the literature. This paper proposes a finite element analysis method for LTUVAM of UD-CF/PPS processes. The kinematic analysis of the LTUVAM is proposed first, then the mechanism of surface formation during UD-CF/PPS milling process is provided. A simulation method which could simultaneously achieve both longitudinal and torsional vibration motions is introduced in the finite element model, enabling the simulation of LTUVAM of UD-CF/PPS composites. The experimental validations were conducted under both CM and LTUVAM conditions with three different cutters, demonstrating that cutting force simulations have significant agreement with experimental data, and both simulation and experiment indicate that LTUVAM produces superior surface quality compared to CM; the fiber debonding at the microscopic level could be eliminated and the height of machined surfaces could be significantly reduced when LTUVAM is utilized. These findings could also open avenues for clarification of other scientific queries such as cutting parameters optimization, cutting tool selection, and modeling of the UD-CF/PPS drilling process.