Experimental investigations on ultrasonic elliptical vibration turning of SiCp/Al composites

This study identifies key factors affecting SiCp/Al surface formation in ultrasonic elliptical vibration assisted turning (UEVT) and conventional turning (CT) by scratch tests, end face cutting experiments and theoretical analysis. It also evaluates cutting parameters' effects on deformation of SiCp/Al. Experimental findings underscore theimportance of vibration effect and removal rate. At lower cutting speeds, the ironing effect results in a dense morphology during UEVT that is advantageous for enhancing both surface quality and microhardness. The high removal speed increases the particle-tool interaction, promotes the generation and propagation of cracks indeformation zone. Specifically, at a reasonable cutting speed (200 mm/min), the utilization of vibration results in a 59% reduction in surface roughness and a commendable enhancement in microhardness, coupled with a significant suppression of tool wear. The results of this study are expected to provide positive theoretical recommendations for improving the machinability of SiCp/Al in UEVT.