Skip to main content
SpringerLink
Log in

Experimental study on cutting force and surface quality in ultrasonic vibration-assisted milling of C/SiC composites

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Carbon fiber-reinforced silicon carbide matrix (C/SiC) composites are typical difficult-to-cut materials due to high hardness and brittleness. Aiming at the problem of the serious high cutting force and poor surface quality in conventional milling (CM) C/SiC composite process, ultrasonic vibration-assisted milling (UVAM) and conventional milling tests with a diamond-coated milling cutter were conducted. The results showed that reducing the feed per tooth, cutting depth, or increasing the cutting speed can reduce the average cutting force, and increasing the ultrasonic amplitude, the average cutting force decreases first and then increases. With the assistance of ultrasonic vibration, the maximum reduction rates of average cutting forces Fx, Fy, and Fz were 43.7%, 29.16%, and 68.09%.The ultrasonic vibration assisting effect does not significantly improve the damage of materials such as fiber breakage during processing. The ultrasonic vibration assisting effect improves the quality of processing edges. It is found that reducing feed per tooth, cutting depth, or increasing cutting speed can reduce surface roughness and increasing the ultrasonic amplitude reduces the surface roughness first and then increases. On the whole, the surface roughness of C/SiC ultrasonic vibration milling is slightly smaller than that of conventional machining.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14

Similar content being viewed by others

References

  1. Faraz A, Biermann D, Weinert K (2009) Cutting edge rounding: an innovative tool wear criterion in drilling CFRP composite laminates. Int J Mach Tool Manu 49(15):1185–1196

    Article  Google Scholar 

  2. Bhosale SB, Pawade RS, Brahmankar PK (2014) Effect of process parameters on MRR, TWR and surface topography in ultrasonic machining of alumina–zirconia ceramic composite. Ceram Int 40(8):12831–12836

    Article  Google Scholar 

  3. Karpat Y, Bahtiyar O, Değer B (2012) Mechanistic force modeling for milling of unidirectional carbon fiber reinforced polymer laminates. Int J Mach Tool Manu 56:79–93

    Article  Google Scholar 

  4. Jahromi AS, Bahr B (2010) An analytical method for predicting cutting forces in orthogonal machining of unidirectional composites. Compos Sci Technol 70(16):2290–2297

    Article  Google Scholar 

  5. Tsao CC (2008) Thrust force and delamination of core-saw drill during drilling of carbon fiber reinforced plastics (CFRP). Int J Adv Manuf Technol 37(1-2):23–28

    Article  Google Scholar 

  6. Patil S, Joshi S, Tewari A et al (2013) Modelling and simulation of effect of ultrasonic vibrations on machining of Ti6Al4V. Ultrasonics 54(2):694–705

    Article  Google Scholar 

  7. Muhammad R, Ahmed N, Demiral M, Roy A, Silberschmidt VV (2011) Computational study of ultrasonically-assisted turning of Ti alloys. Adv Mater Res 223:30–36

    Article  Google Scholar 

  8. Henerichs M, Voss R, Fz K et al (2015) Machining of carbon fiber reinforced plastics: Influence of tool geometry and fiber orientation on the machining forces. CIRP J Manuf Sci Technol 9:136–145

    Article  Google Scholar 

  9. Liu Q, Huang G, Xu X, Fang C, Cui C (2018) Influence of grinding fiber angles on grinding of the 2D−Cf/C−SiC composites. Ceram Int 44(11):12774–12782

    Article  Google Scholar 

  10. Azmi AI, Lin RJT, Bhattacharyya D (2013) Machinability study of glass fibre-reinforced polymer composites during end milling. Int J Adv Manuf Technol 64(1-4):247–261

    Article  Google Scholar 

  11. Eneyew ED, Ramulu M (2014) Experimental study of surface quality and damage when drilling unidirectional CFRP composites. J Mater Res Technol 3(4):354–362

    Article  Google Scholar 

  12. El-Hofy MH, Soo SL, Aspinwall DK et al (2011) Factors affecting workpiece surface integrity in slotting of CFRP. Proc Eng 19(1):94–99

    Article  Google Scholar 

  13. Altintas Y (2012) Manufacturing automation: metal cutting mechanics, machine tool vibrations, and CNC design[M]. Cambridge University Press, Cambridge

    Google Scholar 

  14. Wang H, Qin X, Wu D et al (2017) Optimization of cutting parameters in helical milling of carbon fiber reinforced polymer. Trans Tianjin Univ 24(15):1–10

    Google Scholar 

  15. Teimouri R, Amini S, Mohagheghian N (2017) Experimental study and empirical analysis on effect of ultrasonic vibration during rotary turning of aluminum 7075 aerospace alloy. J Manuf Process 26:1–12

    Article  Google Scholar 

  16. Karpat, Bahtiyar O, Deger B (2012) Milling force modelling of multidirectional carbon fiber reinforced polymer laminates. Proc Cirp 1:460–465

    Article  Google Scholar 

Download references

Funding

This work is supported by the National Natural Science Foundation of China (grant no. 51375055)

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Beijing Institute of Technology, No. 5 South Zhongguancun Street, Haidian District, Beijing, 100081, People’s Republic of China

    Liu Yang, Liu Zhibing, Wang Xibin & Huang Tao

  2. Key Laboratory of Fundamental Science for Advanced Machining, Beijing Institute of Technology, No. 5 South Zhongguancun Street, Haidian District, Beijing, 100081, People’s Republic of China

    Liu Zhibing & Wang Xibin

Authors
  1. Liu Yang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Liu Zhibing
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Wang Xibin
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Huang Tao
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Liu Zhibing.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Yang, L., Zhibing, L., Xibin, W. et al. Experimental study on cutting force and surface quality in ultrasonic vibration-assisted milling of C/SiC composites. Int J Adv Manuf Technol 112, 2003–2014 (2021). https://doi.org/10.1007/s00170-020-06355-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-020-06355-x

Keywords

Search

Navigation