Kinematic Analysis of SiCp/Al Composites under Ultrasonic Vibration-assisted Milling and Machinability Assessment

Kinematic Analysis of SiCp/Al Composites under Ultrasonic Vibration-assisted Milling and Machinability Assessment | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Kinematic Analysis of SiCp/Al Composites under Ultrasonic Vibration-assisted Milling and Machinability Assessment Changhe Ji, Shuguo Hu, Wenhao Xu, Xiaoming Wang, Liandi Xu, Haiyuan Xin, and 7 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-6912233/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 10 Oct, 2025 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 5 You are reading this latest preprint version Abstract Silicon carbide reinforced aluminum matrix composites (SiCp/Al) have emerged as critical materials in advanced sectors such as aerospace, automotive, and electronic devices due to their exceptional mechanical and thermal properties. However, the anisotropy and heterogeneity of SiCp/Al composites result in complex machining mechanisms and severe surface defects, thereby limiting their application in specialized precision fields. Ultrasonic vibration-assisted milling (UAM), which introduces high-frequency vibrations to enhance cutting mechanics, presents a promising approach to improving the milling performance of SiCp/Al composites. First, the kinematics of the tool–workpiece interaction during ultrasonic milling were analyzed, and the separation time per cycle between the tool and workpiece was derived. Second, single-factor experiments investigating spindle speed, feed rate, milling depth, and ultrasonic amplitude identified an optimal surface roughness at an ultrasonic amplitude of 4 μm. Compared with conventional milling (CM), the surface roughness parameters Ra, Rz, Sa, and Sq decreased by 39.24%, 15.06%, 22.00%, and 21.01% respectively, while the surface fractal dimension was reduced by 3.47%. Finally, an orthogonal array design was implemented for the aforementioned parameters. Through range analysis of fractal dimension and surface roughness, the optimal parameter combination was determined as: n = 9000 r/min, ap = 50 μm, Vf = 30 mm/min, A = 4 μm. This research delivers a technical foundation for enhancing the machining quality of SiCp/Al composites through UAM. Ultrasonic vibration SiCp/Al composites Milling Kinematics Full Text Cite Share Download PDF Status: Published Journal Publication published 10 Oct, 2025 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Major Revisions Needed 16 Sep, 2025 Reviewers agreed at journal 10 Jul, 2025 Reviewers invited by journal 23 Jun, 2025 Editor assigned by journal 23 Jun, 2025 First submitted to journal 17 Jun, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-6912233","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":475176309,"identity":"f17f1221-b49c-4acb-bbfd-9cada78ff201","order_by":0,"name":"Changhe Ji","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Changhe","middleName":"","lastName":"Ji","suffix":""},{"id":475176310,"identity":"4ce8122f-eebf-45b1-b6f9-4bb35256ddf6","order_by":1,"name":"Shuguo 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However, the anisotropy and heterogeneity of SiCp/Al composites result in complex machining mechanisms and severe surface defects, thereby limiting their application in specialized precision fields. Ultrasonic vibration-assisted milling (UAM), which introduces high-frequency vibrations to enhance cutting mechanics, presents a promising approach to improving the milling performance of SiCp/Al composites. First, the kinematics of the tool–workpiece interaction during ultrasonic milling were analyzed, and the separation time per cycle between the tool and workpiece was derived. Second, single-factor experiments investigating spindle speed, feed rate, milling depth, and ultrasonic amplitude identified an optimal surface roughness at an ultrasonic amplitude of 4 μm. Compared with conventional milling (CM), the surface roughness parameters Ra, Rz, Sa, and Sq decreased by 39.24%, 15.06%, 22.00%, and 21.01% respectively, while the surface fractal dimension was reduced by 3.47%. Finally, an orthogonal array design was implemented for the aforementioned parameters. Through range analysis of fractal dimension and surface roughness, the optimal parameter combination was determined as: n = 9000 r/min, ap = 50 μm, Vf = 30 mm/min, A = 4 μm. 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