Wear modelling and experimental research on diamond coated tool ultrasonic longitudinal-torsional vibration grinding and polishing of SiCp/Al composites

The substantial discrepancy in cutting properties between the Al matrix and SiC particles within the aluminum-based silicon carbide (SiCp/Al) composition results in severe tool wear during machining operations. This significantly affects the surface quality of the workpiece. Texture boron-doped micro and nano diamond-coated tools are prepared in this paper to study such problems. The tools are then used to conduct sliding friction experiments and ultrasonic longitudinal-torsional vibration, abrasion and polishing machining experiments on SiCp/Al with a volume fraction of 45 %. A tool wear model has been established based on the wear delamination theory. The sliding friction experiment has yielded an average friction coefficient of 0.22 between diamond-coated tools and SiCp/Al, which reduces the coefficient of friction by 57.7 % compared with cemented carbide tools. Furthermore, the surface quality of the wear marks is significantly improved. The tool wear under different machining parameters is analyzed by ultrasonic longitudinal-torsional vibration grinding and polishing experiments, and the validity of the wear model is verified with a maximum error value of 19.3 %. In comparison with conventional machining methodologies, ultrasonic longitudinal-torsional vibration machining has been demonstrated to enhance machining efficiency, improve the surface quality of the workpiece, prolong the service life of the tool, and reduce the cutting force by a maximum of 48.75 %. Concurrently, it has been observed to augment the cutting force of diamond-coated tools during standard operation.