Unraveling the removal mechanisms of ultrasonic vibration-assisted grinding of continuous fiber-reinforced metal matrix composites: experiment and simulation model

Abstract

Continuous fiber-reinforced metal matrix composites (CFMMCs), reinforced by ceramic fibers (e.g., Al₂O₃ and SiC fibers) in a tough metal matrix, are extensively utilized in aerospace applications, such as engine casings and piston rods, because of their excellent high-temperature resistance and creep resistance. However, their heterogeneous composition presents machining challenges, including fiber pull-out, matrix adhesion, and increased tool wear. Ultrasonic vibration-assisted grinding (UVAG) effectively reduces grinding forces and abrasive wear. However, research on abrasive machining of specific CFMMCs is lacking. This study conducted single-grain cubic boron nitride grinding on SiC_f/TC17 with UVAG and compared the material removal mechanisms along two different directions (longitudinal fiber [LF] and transverse fiber [TF]). A simulation model was proposed to reveal the stress distribution and its propagation. Results showed that UVAG could effectively reduce grinding forces along both directions, with an average reduction of about 17.8% compared with conventional grinding. SiC fibers were removed in three models: micro-fractures, macro-fractures, and pull-outs. The introduction of ultrasonic energy mitigated fiber damage. The simulation model was consistent with Removal Model 1. The matrix’s surface stress during grinding along LF was more concentrated than that during grinding along TF under the action of the abrasive grain. The proposed model helps understand the removal behavior of CFMMCs. This research is expected to enhance the comprehension of abrasive machining of CFMMCs and facilitate their application in the aerospace field.

Graphical abstract

Keywords

continuous fiber-reinforced metal matrix composites / material removal mechanism / ultrasonic vibration-assisted grinding / simulation model

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