Research on contact friction characteristics of SiCp/Al tool-chip under quasi-intermittent vibration assisted swing cutting

Abstract

In order to reduce the cutting force and tool wear during the processing of aluminum based silicon carbide composite materials, this study deeply explores the machining mechanism of quasi intermittent vibration assisted swing cutting of aluminum based silicon carbide composite materials. To this end, a tool-chip friction model was formulated to scrutinize the effects of cutting forces and chip formation under a spectrum of machining parameters. The findings indicate that the cutting force escalates with an increase in cutting depth and exhibits a trend of initial decrease followed by an increase with the rise in swing frequency. The tool swing characteristic of QVASC demonstrates superiority over orthogonal cutting (OC) in facilitating chip breakage. The experimental results show that when the cutting rate and vibration frequency are 10 m/min and 150 Hz, respectively, the length of the chips is the shortest. When the cutting depth and vibration frequency are 150 Hz, the cutting force is the smallest. The directional shifts in chip flow, instigated by the tool’s oscillation, induce horizontal bending of the chips, thereby easing their fragmentation and expediting chip removal, which in turn diminishes chip-tool interface friction. Moreover, as the cutting speed rises, the average length of chips tends to elongate. However, an increase in tool swing angle and frequency counteracts this trend, reducing the average chip length, with the frequency’s impact being notably pronounced. These insights provide direction for the application of SiCp/Al composite materials and the advancement of quasi intermittent vibration assisted swing cutting technology.