Kinematic Analysis of SiCp/Al Composites under Ultrasonic Vibration-assisted Milling and Machinability Assessment
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Silicon carbide reinforced aluminum matrix composites (SiCp/Al) have emerged as critical materials in advanced sectors such as aerospace, automotive, and electronic devices due to their exceptional mechanical and thermal properties. However, the anisotropy and heterogeneity of SiCp/Al composites result in complex machining mechanisms and severe surface defects, thereby limiting their application in specialized precision fields. Ultrasonic vibration-assisted milling (UAM), which introduces high-frequency vibrations to enhance cutting mechanics, presents a promising approach to improving the milling performance of SiCp/Al composites. First, the kinematics of the tool–workpiece interaction during ultrasonic milling were analyzed, and the separation time per cycle between the tool and workpiece was derived. Second, single-factor experiments investigating spindle speed, feed rate, milling depth, and ultrasonic amplitude identified an optimal surface roughness at an ultrasonic amplitude of 4 μm. Compared with conventional milling (CM), the surface roughness parameters Ra, Rz, Sa, and Sq decreased by 39.24%, 15.06%, 22.00%, and 21.01% respectively, while the surface fractal dimension was reduced by 3.47%. Finally, an orthogonal array design was implemented for the aforementioned parameters. Through range analysis of fractal dimension and surface roughness, the optimal parameter combination was determined as: n = 9000 r/min, ap = 50 μm, Vf = 30 mm/min, A = 4 μm. This research delivers a technical foundation for enhancing the machining quality of SiCp/Al composites through UAM.