Modeling and prediction of the cutting temperature of SiCp/Al composites for quasi-intermittent vibration assisted swing cutting

Abstract

SiCp/Al is widely used in the manufacturing of high-end equipment, but it is difficult to process and poor in surface quality. Conversely, Quasi-intermittent Vibration Assisted Swing Cutting (QVASC) combines the intermittent cutting mechanism of EVC (Elliptical Vibration Cutting) while effectively reducing cutting forces via its unique offset swing motion. This study undertakes detailed analysis of the kinematics and friction characteristics intrinsic to QVASC. A predictive model for cutting temperature is subsequently developed, incorporating the influence of reinforcing particles. This model primarily ascribes the generated heat to two sources: the shear heat source and the frictional heat source, further examining resultant temperature distributions in the tool, workpiece, and chip alongside corresponding heat partition ratios. Single-factor experiments were conducted with spindle speed, cutting depth, frequency, amplitude, and feed amount as parameters. Theoretical and experimental cutting temperatures are compared, revealing consistent trends. Calculated average relative errors for these parameters are 4.65%, 9.50%, 3.32%, 2.58%, and 3.81% respectively. These errors lie within acceptable limits, validating the theoretical model’s accuracy. Consequently, this research provides valuable insights into the QVASC cutting mechanism and offers an efficient approach for determining optimal cutting parameters.