PSI - Issue 37

Jin Kim et al. / Procedia Structural Integrity 37 (2022) 282–291 Kim et al./ Structural Integrity Procedia 00 (2021) 000 – 000

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Nomenclature , , , , Johnson-Cook plasticity constants depth-of-cut − peak-to-peak amplitude 1 , 2 , 3 , 4 , 5 Johnson-Cook damage constants strain 0 reference strain failure strain plastic strain ̇ strain rate 0̇ reference strain rate feed frequency cutting force tool radius arithmetical mean height , ideal arithmetical mean height surface arithmetical mean height von mises flow stress mean stress equivalent stress temperature reference temperature melting temperature cutting speed 1. Introduction

Silicon carbide reinforced aluminium (SiCp/Al) composites are excellent engineering materials for component manufacture in aerospace, automotive, and energy industries, thanks to their high strength-to-weight ratio and wear resistance properties by Tzamtzis et al. (2009). Machining these materials poses challenges as the improved strength of the composites with abrasive SiC particles leads to high tool wear by Tomac et al. (1992), and Manna and Bhattacharayya (2005). Studies show that large particle size and volume fraction introduces excessive tool wear with particle fracture that causes poor surface finish post-machining by Kesarwani et al. (2020), and Nirala et al. (2020). It is generally understood that carbide tools are not desirable for machining such materials by Durante et al. (1997), although fixed rhombic tooling may be effective by Manna and Bhattacharayya (2003). The use of PCD tools shows improved tool life at low cutting speeds due to their excellent wear resistance and strength when compared to carbide tools. However, the cost of PCD tools is approximately tenfold higher than conventional carbide tools, which makes the machining process expensive. It is known that the tool wear of PCD tools is mainly associated with high cutting speed (>80 m/min), hence, low cutting speed is recommended, which increases the overall machining time (and costs) by Ciftci et al (2004), and Davim and Baptista (2000). Ultrasonically assisted machining is a hybrid machining process, where mechanical vibrations at high frequencies (>20 kHz) are imposed on the cutting tool tip during the machining process. Studies show that this machining technique reduces average cutting forces, improves surface finish inducing compressive residual stresses in the machined component, which in turn improves its fatigue life by El-Kady and Fathy (2014), Kim et al. (2019), and Zhou et al. (2010). In this paper, we carry out a comparative study of ultrasonically assisted turning and conventional turning on two types of SiCp/Al composites. We report on the cutting forces, surface quality, and tool wear using cemented carbide