Study of cutting force of SiCp/Al composites based on acoustic-plasticity intrinsic model

Ultrasonic vibration-assisted cutting (UVAC) is widely used in metal manufacturing due to its high-frequency acoustic energy benefits. However, constitutive models for UVAC of SiCp/Al composites often rely on the Johnson-Cook (JC) model, neglecting the ultrasonic-induced acoustic softening effect. To address this, we developed an acoustoplastic constitutive model for SiCp/Al by integrating dislocation density and crystal plasticity theories, incorporating stress superposition and acoustic softening. Using this model for cutting simulations and experiments, cutting forces were studied. The proposed acoustoplastic model's accuracy improvements in predicting UVAC cutting forces for SiCp/Al were systematically compared against the traditional JC model.