目的 SiCp/Al因其高比强度和低热膨胀系数,在航空航天及国防工业中具有广泛应用。然而,该材料的高硬度与显著的非均质性导致传统机械加工中存在切削力过大、颗粒脆性断裂及严重的亚表面损伤等缺陷。本文提出采用脉冲激光-超声振动辅助切削（PLUVAT）加工技术,通过复合能场的协同作用改善加工表面完整性。方法 研究通过构建有限元切削模型,分析了热-力耦合场对颗粒破碎路径的影响,并结合SEM形貌图与EBSD显微表征技术从多尺度视角深入探究了亚表面损伤的抑制机理。结果 研究表明,与传统加工（CT）相比,PLUVAT工艺下表面粗糙度显著下降38.5%。仿真图揭示了脉冲激光产生的瞬时热软化效应降低了Al基体对SiC颗粒的约束应力,而超声波的冲击效应改变了应力的传递方向,有效抑制了微裂纹向基体内部的扩展。亚表面层组织演变分析发现,复合能场触发了基体组织的显著演化。EBSD分析显示,加工区域发生了明显的动态再结晶现象,特定晶向的分布频率因能场导致的晶格转动而改变。此外,PLUVAT促使加工诱导的位错发生合并,亚表面层内最大局部取向差（KAM）相比CT降低了22%,有效释放了由于变形产生的残余内应力,提高了晶粒延伸率。结论 综上所述,PLUVAT通过优化颗粒破碎模式及诱导基体微观组织回复,实现了对亚表面损伤的深度抑制。本研究揭示了复合能场与非均质材料相互作用的微观机制,为SiCp/Al的精密制造提供了理论支撑与工艺指导。
Abstract
SiCp/Al composites are increasingly utilized in critical fields such as aerospace engineering, advanced defense industries, and precision instrumentation, owing to their exceptional high specific strength, high specific modulus, superb wear resistance, and low coefficient of thermal expansion. Nevertheless, the extreme physical and mechanical heterogeneity between the hard-brittle reinforcement particles and the ductile metal matrix inherently results in poor machinability during conventional machining (CT). It severely triggers excessive cutting forces, accelerated tool wear, irregular particle dislodgement, brittle fracture, and deep subsurface damage (SSD). These macro- and micro-defects severely degrade the fatigue life and operational reliability of the machined components. To address these limitations, this work introduces a novel hybrid cutting paradigm designated as pulsed laser-ultrasonic vibration-assisted cutting (PLUVAT), aiming to significantly enhance the machined surface integrity by exploiting the micro-synergistic coupling effects of thermal, mechanical, and acoustic energy fields.
In this work, a multi-phase orthogonal cutting finite element (FE) simulation model incorporating the Johnson-Cook model (JC) for the aluminum matrix and the Drucker-Prager model (DP) for the SiC particles is established via the Abaqus/Explicit platform. The FE model systematically investigates the regulation mechanism of the coupled stress field on the micro-fracture pathways of the reinforcement particles. Concurrently, comparative cutting experiments are implemented. Combined with scanning electron microscopy (SEM) morphological investigations and electron backscatter diffraction (EBSD) microstructural characterization, the underlying suppression mechanisms governing the subsurface damage are comprehensively elucidated from a multi-scale perspective.
The results demonstrate that, compared with conventional cutting, the surface roughness (Sa) under the PLUVAT configuration is drastically reduced by 38.5%. Numerical simulations and morphological characterizations explicitly reveal the physical synergistic mechanisms of the coupled energy fields. The transient high-energy thermal effect induced by the pulsed laser radiation promotes localized thermal softening of the aluminum matrix. This localized softening markedly minimizes the rigid constraining stress exerted by the matrix on the hard-brittle particles, transitioning the particle removal mode toward stable plastic shearing or regular fracture. Simultaneously, the high-frequency intermittent impact effect of ultrasonic vibration effectively alter the transmission direction and the triaxial state of the dynamic cutting stress. This acoustic effect deflects or arrests the propagation of brittle microcracks within the skin layer, thereby preventing large-scale particle pull-out pits and deep-seated subsurface microcracks. Regarding the microstructural evolution within the subsurface layer, the coupled energy fields trigger a profound transformation of the matrix configuration. EBSD microstructural analysis verifies that noticeable dynamic recrystallization (DRX) occurred within the severely deformed zone under the mutual driving forces of intense shear deformation and transient laser thermal effects, manifesting as an abundance of fine equiaxed grains. The energy-field-induced severe lattice rotation significantly shifts the distribution frequency of specific crystallographic orientations and micro-textures. Furthermore, the thermal activation energy from the laser and the dynamic strain energy from the ultrasonic vibration collaboratively accelerate the mutual movement and efficient coalescence of machining-induced dislocations. Consequently, the geometrically necessary dislocation (GND) density within the subsurface layer drops sharply, which leads to a 22% reduction in the maximum kernel average misorientation (KAM) compared with CT. This microstructural recovery not only successfully releases the residual internal stresses accumulated from severe mechanical deformation but also substantially prolongs the grain elongation and improves microstructural homogeneity. In summary, the PLUVAT process achieves deep and precise suppression of subsurface damage by optimizing the particle fracture modes at the micro-scale and inducing matrix microstructural recovery and recrystallization. This study clarifies the intrinsic mechanical and physical interactions between external coupled energy fields and complex heterogeneous materials, providing crucial theoretical support and frontier technical guidance for the precision manufacturing of high-performance SiCp/Al composite components.
关键词
SiCp/Al复合材料 /
脉冲激光-超声振动辅助加工 /
亚表面损伤 /
SEM /
EBSD技术 /
KAM
Key words
SiCp/Al composites /
pulsed laser-ultrasonic vibration-assisted cutting (PLUVAT) /
subsurface damage /
SEM /
EBSD technique /
KAM
{{custom_sec.title}}
{{custom_sec.title}}
{{custom_sec.content}}
参考文献
[1] 邢绍美, 马建平. 碳化硅铝基复合材料的应用与加工[J]. 航天返回与遥感, 1998, 19(2): 45-49.
XING S M, MA J P.The Application and Process of SiC/Al Composite Materials[J]. Spacecraft Recovery & Remote Sensing, 1998, 19(2): 45-49.
[2] HAO Z P, XU Y S, FAN Y H, et al.Overview of Research on Machining Mechanism of Aluminum-Based Silicon Carbide Composites (SiCp/Al)[J]. The International Journal of Advanced Manufacturing Technology, 2024, 133(7): 3133-3149.
[3] 梁洪涛, 徐亮, 方胜, 等. 激光诱导氧化辅助铣削SiCp/Al复合材料试验研究[J]. 科学技术与工程, 2020, 20(31): 12770-12775.
LIANG H T, XU L, FANG S, et al.Experimental Study on Laser-Induced Oxidation Assisted Milling of SiCp/Al Composite[J]. Science Technology and Engineering, 2020, 20(31): 12770-12775.
[4] DU H H, YIP W S, SUN W T, et al.In-Situ Laser- Assisted Ultraprecision Cutting of WC-Co Cemented Carbide for Creating Microstructure Arrays[J]. Ceramics International, 2023, 49(23): 38698-38707.
[5] WANG M, ZHENG Z D, WU Z P, et al.Investigation on the Machinability of SiCp/Al Composite by In-Situ Laser Assisted Diamond Cutting[J]. Journal of Materials Processing Technology, 2023, 318: 118044.
[6] WEI C, GUO W, PRATOMO E S, et al.High Speed, High Power Density Laser-Assisted Machining of Al-SiC Metal Matrix Composite with Significant Increase in Productivity and Surface Quality[J]. Journal of Materials Processing Technology, 2020, 285: 116784.
[7] XIA C Y, LIN J Q, LU M M, et al.Study on Machinability of SiCp/Al Composites by Laser-Induced Oxidation-Assisted Turning[J]. Journal of Materials Engineering and Performance, 2025, 34(5): 4315-4327.
[8] SHUANG C.Study on Cutting Force and Surface Quality of SiCp/Al Composite Materials Assisted by Laser Cutting[D]. Changchun: Changchun University of Technology. 2024.
[9] LIN J Q, YU B J, GU Y, et al.Effect of Pulsed Laser on Chips Formation and Surface Morphology of SiCp/Al during Turning[J]. Applied Surface Science, 2025, 696: 162982.
[10] ZHENG Z D, CHEN D C, HAN S Y, et al.Investigation on Material Removal and Damage Suppression Mechanism of Sip/Al Composites with In-Situ Laser-Assisted Cutting[J]. Journal of Manufacturing Processes, 2025, 150: 1004-1017.
[11] YOU K Y, YAN G P, LUO X C, et al.Advances in Laser Assisted Machining of Hard and Brittle Materials[J]. Journal of Manufacturing Processes, 2020, 58: 677-692.
[12] YU B J, GU Y, LIN J Q, et al.Synergistic Effect of Laser-Induced Plastic Deformation and Ultrasonic Chip Fracture on Surface Quality and Tool Life during SiCp/Al Turning[J]. Applied Surface Science, 2026, 727: 165994.
[13] YANG Z C, ZHU L D, ZHANG G X, et al.Review of Ultrasonic Vibration-Assisted Machining in Advanced Materials[J]. International Journal of Machine Tools and Manufacture, 2020, 156: 103594.
[14] ZHA H T, FENG P F, ZHANG J F, et al.Material Removal Mechanism in Rotary Ultrasonic Machining of High-Volume Fraction SiCp/Al Composites[J]. The International Journal of Advanced Manufacturing Technology, 2018, 97(5): 2099-2109.
[15] Wang J L, Yuan S M, Li Q L, Gao X X.Simulation study of force and thermal characteristics on SiCp/Al ultrasonic elliptical vibration turning[J]. Aeronaut. Manuf. Technol, 2023, 66(17): 79-88, 109.
[16] NIU Q L, DAI F P, JING L, et al.Study on the Processing Performance of 60% SiCp/Al Composite Materials Assisted by Longitudinal and Torsional Ultrasonic Vibration Milling[J]. The International Journal of Advanced Manufacturing Technology, 2024, 135(1): 247-266.
[17] ZHANG B, CHEN G J, CHEN Z, et al.Ultrasonic Elliptic Vibration Assisted Turning SiCp/Al Composite Surface Morphology[J]. Journal of Manufacturing Processes, 2025, 141: 1071-1083.
[18] 马国红, 张加力, 闫帆, 等. SiCp/Al复合材料在常规与超声振动辅助条件的切削过程和表面形成的有限元分析[J]. 制造技术与机床, 2024(4): 51-56.
MA G H, ZHANG J L, YAN F, et al.Finite Element Analysis of Cutting Process and Surface Formation of SiCp/Al Composites under Conventional and Ultrasonic Vibration Assisted Conditions[J]. Manuf. Technol. Mach. Tool, 2024(4): 51-56.
[19] HUANG W H, YU D P, ZHANG X Q, et al.Ductile-Regime Machining Model for Ultrasonic Elliptical Vibration Cutting of Brittle Materials[J]. Journal of Manufacturing Processes, 2018, 36: 68-76.
[20] LI B, XIANG D H, PENG P C, et al.Experimental and FEM Study of Surface Formation and Deformation Mechanism of SiCp/Al Composites in Laser-Ultrasonic Vibration Assisted Turning[J]. Ceramics International, 2023, 49(9): 13510-13519.
[21] KIM J, ZANI L, ABDUL-KADIR A, et al.Hybrid-Hybrid Turning of Micro-SiCp/AA2124 Composites: A Comparative Study of Laser-and-Ultrasonic Vibration-Assisted Machining[J]. Journal of Manufacturing Processes, 2023, 86: 109-125.
[22] DESWAL N, KANT R.Surface Integrity Analysis of Aluminum 3003 Alloy during Ultrasonic-Vibration-Laser Assisted Turning[J]. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2024, 238(6/7): 1057-1068.
[23] ZHOU W D, GU Y, LIN J Q, et al.Pulsed Laser Ultrasonic Vibration-Assisted Cutting of SiCp/Al Composites through Finite Element Simulation and Experimental Research[J]. Machines, 2024, 12(1): 71.
[24] HAN J, ZHAO C, WANG Y, et al.Research Progress on High Efficiency and Low Damage Processing Technology of SiCp/Al Composite[J]. International Core Journal of Engineering, 2024, 10(4): 99-113.
[25] XIAO G J, WANG J Z, ZHU S W, et al.A Review of Research on Material Removal Mechanisms for Laser- Assisted Machining of Difficult-to-Machine Materials[J]. Surface Science and Technology, 2023, 1(1): 8.
[1] JIAO F, ZHANG M J, NIU Y.Optimization of Tungsten Carbide Processing Parameters for Laser Heating and Ultrasonic Vibration Composite Assisted Cutting[J]. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 2019, 233(12): 4140-4153.
[26] ZHANG C J, QIU Y X, JIAO F, et al.Research on Temperature Characteristics and the Machining Process in Laser Ultrasonic-Assisted Milling of Cemented Carbide[J]. International Journal of Refractory Metals and Hard Materials, 2025, 128: 107031.
[27] FU B, GU Y, LIN J Q, et al.Influence Mechanism of Ultrasonic Vibration and Pulsed Laser on the Surface Formation of SiCp/Al in Cutting[J]. International Journal of Thermal Sciences, 2025, 218: 110143.
[28] LU S J, LI Z Q, ZHANG J J, et al.Finite Element Investigation of the Influence of SiC Particle Distribution on Diamond Cutting of SiCp/Al Composites[J]. Nanomanufacturing and Metrology, 2020, 3(4): 251-259.
[29] LI Y C, ZHANG X, WANG C.Cutting Force Prediction Model for Elliptical Vibration Cutting SiCp/Al Based on Three-Phase Friction Theory[J]. Applied Sciences, 2021, 11(22): 10737.
[30] 王进峰, 赵久兰, 储开宇. SiCp/Al复合材料切削力的仿真研究[J]. 系统仿真学报, 2018, 30(4): 1566-1571.
WANG J F, ZHAO J L, CHU K Y.Simulation Study on Cutting Force of SiCp/Al Composite[J]. Journal of System Simulation, 2018, 30(4): 1566-1571.
[31] 段春争, 孙伟, 傅程, 等. 切削SiCp/Al复合材料三相摩擦系数建模与模拟[J]. 哈尔滨工程大学学报, 2019, 40(3): 509-517.
DUAN C Z, SUN W, FU C, et al.Three-Phase Friction Coefficient Modeling and Simulation in the Cutting Process of SiCp/ Al Composites[J]. Journal of Harbin Engineering University, 2019, 40(3): 509-517.
[32] LAGHARI R A, LI J G, WU Y X.Study of Machining Process of SiCp/Al Particle Reinforced Metal Matrix Composite Using Finite Element Analysis and Experimental Verification[J]. Materials, 2020, 13(23): 5524.
[33] 林洁琼, 吴明磊, 刘思洋, 等. 超声振动辅助切削SiCp/Al复合材料的加工机理及试验[J]. 中国表面工程, 2024, 37(2): 182-198.
LIN J Q, WU M L, LIU S Y, et al.Processing Mechanism and Experiment of Ultrasonic Vibration Assisted Cutting of SiCp/Al Composites[J]. China Surface Engineering, 2024, 37(2): 182-198.
基金
国家自然科学基金青年科学基金项目（52405452）; 吉林省自然科学基金（20260102046JC）
PDF(31632 KB)
渝公网安备 50010702501715号 渝ICP备15012534号-3
