Study on the edge defects of high volume fraction 70% SiCp/Al composites in ultrasonic-assisted milling

Directing at the hard machinability of high volume fraction 70% SiCp/Al composites, a longitudinal and torsional ultrasonic-assisted milling (LTUAM) method is proposed to improve edge quality machining efficiency. By observing metallographic structure material, three-dimensional (3D) finite element model random distribution spherical, elliptical polygonal SiC particles established analyzed by ABAQUS simulation software. The formation mechanism defects, stress distribution, defect characteristics effect parameters on forces are investigated during milling. results show that defects appear inlet, outlet middle position, especially more serious position. failure modes mainly include particle pullout, shearing, crushing, moreover, matrix tearing, breakage, burrs, bulges pits. Ultrasonic-assisted (UAM) with certain range ultrasonic amplitude could effectively reduce surface fragmentation rate force, it not only slow down expansion cracks, but also increase plastic flow obtain better compared traditional method. Comparing analysis experimental tests, shows in good agreement tests.