Abstract
To predict the dynamic principal cutting force of aluminum-based silicon carbide composites (SiCp/Al) during ultrasonic elliptical vibration cutting (UEVC), the resistance acting on the PCD tool was divided into four parts according to the different force deformation zones: shear deformation zone, tool rake face-chip interface friction deformation zone, plow force and SiC-reinforced particle fracture force deformation zone, and side-workpiece interface friction deformation zone. Considering the parameters such as shear angle, shear flow strength and uncut deformation thickness, the main cutting force model of the interaction between the tool and the machined material was established by applying the maximum shear stress criterion, the minimum energy principle, the three-phase friction principle shear band model and other related knowledge. Finally, the cutting parameters are determined by the three-factor three-level orthogonal UEVC experiment, and the accuracy of the theoretical mathematical model of the main cutting force is verified. The experimental results show that the maximum relative error between the measured value of the main cutting force and the predicted value calculated by the main cutting force model is 15.28%, and the average relative error is 8.07%, and the accuracy of the main cutting force model is fully proven.
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