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• Propose a new CFRP grinding approach using adjustable multiangle 2D ultrasonic vibration - empowered nanolubricant MQL. • Reveal CFRP removal mechanics and develop a grinding force model under different ultrasonic and lubrication-cooling conditions. • Ultrasonic vibration - empowered nanolubricant MQL effectively reduces CFRP grinding force, especially with a 2D combined ultrasonic vibration angle of 90°. As a weight-reducing material in aerospace applications, carbon fiber reinforced polymer (CFRP) requires precision grinding to ensure the accuracy and assembly of mating positioning surfaces. However, achieving low-damage machining of CFRPs remains challenging. Flood cooling reduces the mechanical properties, while dry grinding deteriorates the surface integrity, making minimum quantity lubrication (MQL) a viable alternative. However, nanolubricants struggle to penetrate the grinding area due to gas barrier obstruction. Consequently, a new CFRP grinding approach using multiangle 2D ultrasonic vibration - empowered nanolubricant MQL was proposed. An analytical force model is crucial for optimizing machining strategies and adjusting parameters. The aim is to reveal grinding mechanics and develop a force model under different ultrasonic and lubrication-cooling conditions. First, a uniform random fiber distribution model and a grinding wheel model were established, and the mechanical properties of the interface were predicted. Then, the intermittent grinding behavior and dynamic stiffnesses of the multiangle 2D ultrasonic vibration-assisted grinding (UVAG) system were investigated based on the geometric kinematics of the grains' trajectory. Furthermore, based on the deformation deflection curve, bending fracture force models for 45°, 90°, and 135° fibers were established with different contact and boundary conditions. The material removal mechanisms of shear and tension-compression buckling in 0° CFRP grinding were revealed, and an elliptical contact normal force model was established. The interlayer shear in 45° CFRPs was analyzed. The longitudinal compressive matrix cracking and fiber shear fracture in the 90° CFRPs were elucidated. Fiber microbuckling and fiber bundle removal of 135° CFRPs were investigated. Finally, grinding force models with different fiber orientation angles (FOAs) were interconnected and experimentally assessed. Experimental assessments demonstrated that the grinding force model has acceptable estimation error and effectively captures the mechanics of CFRPs with different FOAs. [Display omitted] [ABSTRACT FROM AUTHOR]

SiCp/Al composites, known for their outstanding properties, are widely used in aerospace, automotive, and other fields. Despite extensive research, a complete theoretical framework and evaluation system for processing these composites have not yet been established. To enhance their processability, it is crucial to understand how processing-induced characteristics affect their machinability and to establish a robust evaluation system. This study addresses this gap by first reviewing the influence of particle properties on the mechanical properties of SiCp/Al composites. Next, both conventional and advanced machining mechanisms are analyzed, and the processability based on the cutting/grinding forces and surface roughness is evaluated. The results show that advanced machining techniques significantly improve processability compared to conventional methods. The ultrasonic elliptical vibration-assisted turning of the 25 vol% SiCp/Al6061 composites resulted in an 82.4% reduction in the cutting force. Laser-assisted turning of 45 vol% SiCp/Al composites achieved an 89.5% improvement in surface roughness (S a). Finally, we identify research gaps and future challenges in processing SiCp/Al composites, providing technical support and theoretical guidance for both industry and academia. [ABSTRACT FROM AUTHOR]