Modeling and simulation for orthogonal cutting force in ultrasonic vibration–assisted machining in situ TiB₂/Al MMCs

Ultrasonic vibration–assisted machining represents a sophisticated manufacturing technique that offers several significant advantages, such as diminished tool wear and reduced cutting forces when processing hard-to-machine materials. Recent studies have extensively explored the generation and mechanisms of cutting forces in ultrasonic vibration–assisted machining from multiple perspectives. In situ TiB₂/Al metal matrix composites have shown excellent performance in the field of aerospace engines, with a broad application prospect. However, its processing problems have always been a major obstacle to its application development. This study investigated the mechanisms underlying the cutting force generated during ultrasonic vibration–assisted cutting. Kinematic analysis was employed to examine the frictional interactions between the chip and the rake face. It indicates that ultrasonic vibrations exert a substantial influence on frictional behavior. Throughout a complete vibration cycle, the frictional process could be categorized into three distinct phases: the dynamic friction zone, the reverse dynamic friction zone, and the static friction zone. Furthermore, an analytical model of an orthogonal cutting force was developed with consideration of the transient shear angle and the friction reversal. Subsequently, a two-dimensional model was developed utilizing the finite-element simulation method to validate the accuracy of the cutting force model. The results showed that there was a certain degree of error between the theoretical predicted values and the output of the simulation model, and the error was less than 20%. Nevertheless, the observed trend in cutting force variations demonstrated a strong consistency between the two methods.