目的 研究超声椭圆振动对纤维增强铝基复合材料（SiCf/Al）复合材料去除机理及表面质量的影响规律,使得这种加工技术应用于连续纤维增强金属复合材料中。方法 基于ABAQUS显式动力学方法,构建考虑碳化硅纤维、铝基体及界面行为的三维微观切削模型,对普通切削（CC）与超声椭圆振动切削（UEVC）在不同切削深度下的材料去除行为进行对比分析;结合超精密车削实验,对加工表面粗糙度进行测量,实现仿真与实验的交叉验证。结果 UEVC条件下刀具周期性接触-分离特征,这显著降低了切削区应力集中与界面摩擦累积,使纤维断裂趋于局部化与规则化,界面脱黏与拔出现象得到有效抑制;铝基体以稳定剪切流动为主,侧向堆积与翻卷明显减弱,从而获得更均匀的表面形貌。在5~25 μm切深范围内,UEVC所加工的表面粗糙度由0.115 μm增加到0.224 μm,而CC所加工的表面粗糙度由0.195 μm增加到0.442 μm。可以看出,UEVC表面粗糙度整体低于CC,且随切深增加表面质量恶化程度较小,表现出更好的加工稳定性。结论 超声椭圆振动通过改变刀具运动轨迹与载荷作用方式,实现了对纤维脆性断裂行为与基体塑性流动的协同调控,使材料去除由非协调复合损伤向可控剪切主导转变,从而显著改善SiCf/Al复合材料的表面完整性。研究结果可为连续纤维增强金属基复合材料的低损伤高质量加工提供理论依据与工艺参考。
Abstract
Continuous fiber-reinforced metal matrix composites, such as SiC fiber-reinforced aluminum (SiCf/Al), have gained increasing attention in advanced engineering applications for their high specific strength, lightweight nature, and excellent mechanical performance under extreme conditions. However, the inherent heterogeneity and anisotropy of these composites, arising from the coexistence of brittle ceramic fibers, ductile metallic matrices, and interfacial transition zones, pose significant challenges for high-quality machining. During conventional cutting (CC), the mismatch in mechanical properties between the fiber and matrix often results in severe defects, including fiber fracture, interfacial debonding, matrix tearing, and fiber pull-out, ultimately degrading surface integrity and machining stability. To address these challenges, this study systematically explores the material removal mechanism and the development of surface morphology in SiCf/Al composites during ultrasonic elliptical vibration cutting (UEVC). A three-dimensional micromechanical cutting model incorporating SiC fibers, the aluminum matrix, and their interfacial behavior is created using the ABAQUS explicit dynamic method. Comparative simulations between CC and UEVC are carried out at various cutting depths (5-25 μm) to analyze differences in stress distribution, deformation modes, and damage evolution. Within the cutting depth range of 5-25 μm, the surface roughness processed by UEVC increases from 0.115 μm to 0.224 μm, while the surface roughness processed by CC increases from 0.195 μm to 0.442 μm. Additionally, ultra-precision turning experiments are performed to validate the simulation results, with surface roughness measured utilizing white-light interferometry.
The results reveal that UEVC significantly alters the cutting mechanics through its unique tool motion characterized by periodic contact-separation and multi-directional vibration. This intermittent cutting behavior effectively reduces stress concentration and friction accumulation in the cutting zone. Consequently, fiber fracture becomes more localized and regular, while interfacial debonding and fiber pull-out are substantially suppressed. In contrast, under CC conditions, continuous tool-workpiece contact leads to the accumulation of compressive and shear stresses, promoting uncontrolled fiber breakage and extensive interfacial damage. From the perspective of the matrix behavior, the aluminum matrix under UEVC exhibits stable shear-dominated plastic flow with reduced lateral material accumulation and surface pile-up. This contributes to the formation of smoother and more uniform surface morphology. On the contrary, in CC, the matrix undergoes severe plastic side flow and plowing, resulting in pronounced surface irregularities and defects. As the cutting depth increases, both methods exhibit a degradation in surface quality; however, UEVC shows a much slower deterioration rate and superior process stability. Experimental observations further confirm that UEVC produces surfaces with lower roughness and more consistent topography across different cutting depths. The periodic separation between the tool and workpiece reduces instantaneous cutting forces and mitigates secondary damage to the surrounding matrix after fiber fracture. As a result, the synergistic removal of fibers and the matrix is enhanced, transforming the material removal mode from uncontrolled composite damage to a more predictable shear-dominated process. In summary, ultrasonic elliptical vibration cutting effectively improves the machining performance of SiCf/Al composites by modifying the tool-workpiece interaction mechanism and redistributing the cutting load. It enables coordinated control over brittle fiber fracture and ductile matrix deformation, thereby significantly enhancing surface integrity and reducing subsurface damage. This study provides both theoretical insights and experimental evidence for understanding the micro-scale removal mechanisms of heterogeneous composites and offers practical guidance for achieving low-damage, high-quality machining of continuous fiber-reinforced metal matrix composites.
关键词
超声椭圆振动切削 /
SiCf/Al复合材料 /
ABAQUS显式动力学 /
表面粗糙度 /
去除机理 /
表面质量
Key words
ultrasonic elliptical vibration cutting /
SiCf/Al composite /
ABAQUS explicit dynamics /
surface roughness /
removal mechanism /
surface quality
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基金
国家自然科学基金（U24A202961）; 吉林省科学技术厅项目（20260601019RC）
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