Feasibility and tool performance of ultrasonic vibration-assisted milling-grinding SiCf/SiC ceramic matrix composite

As an advanced material, ceramic matrix composites have attracted attention due to their superior properties, such as low density, high strength, and high-temperature resistance. However, it is also a typical difficult-to-cut material with the reinforcement and matrix material being of high hardness and brittleness, which makes the manufacturing of this kind of material an urgent problem. Ultrasonic vibration-assisted machining technique has advantages in decreasing cutting force, reducing tool wear, and improving machinability, making it suitable for machining hard and brittle difficult-to-cut materials. This paper has investigated ultrasonic vibration-assisted milling-grinding SiC fiber reinforced ceramic matrix composite. It aims to understand the feasibility of machining this advanced material and tool performance. Experimental results found that the ultrasonic vibration-assisted machining technique with the proper tool would be a suitable method for this advanced material. The self-designed polycrystalline diamond compact tool had a better performance and tool life. Its tool life was 4.11 times, 12 times, and 50.63 times as long as commonly used 50 mesh brazed diamond tool, 200 mesh brazed diamond tool and 100 mesh electroplated diamond tool, respectively. For a smaller cutting force and tool wear, machining parameters of a more considerable spindle speed, lower feed speed, and small cutting depth would be suggested, with ultrasonic amplitude being 4 μm and frequency being 30 kHz.