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Simulated bone is widely used for surgical simulation, medical training, and especially for medical cutting device testing due to its mechanical properties similar to those of natural bone. However, studies on its cutting characteristics are still limited, especially for the simulated cortical bone. The cutting characteristics of natural cortical bone are often influenced by viscoelasticity and bone fiber structure that affect chip formation, as well as the variation of cutting forces at different cutting speeds or different depths of cut. In this work, orthogonal cutting experiments were performed on simulated cortical bone to investigate chip formation with cutting force variations and compared with bovine cortical bone. Experimental results show that the simulated cortical bone is similar to bovine cortical bone in viscoelasticity. Simulated bone has a relatively homogeneous composition with a simple hierarchy. Therefore, the difference in cutting force at small and large cutting depths is less significant than in natural cortical bone. In addition, because the glass fibers in simulated bone are randomly distributed, they do not accurately reflect the anisotropic properties of natural cortical bone. These findings can contribute to an in-depth understanding of the behavior of simulated bone during the cutting process and guide the improvement of simulated bone to better emulate the cutting characteristics of cadaveric bone for better application in the medical field. [ABSTRACT FROM AUTHOR]

High-performance carbon fiber-reinforced polyether-ether-ketone (CF/PEEK) has been gradually applied in aerospace and automobile applications because of its high strength-to-weight ratio and impact resistance. The dry-machining requirement tends to cause the cutting temperature to surpass the glass transition temperature (Tg), leading to poor surface quality, which is the bottleneck for dry milling of CF/PEEK. Temperature suppression has become an important breakthrough in the feasibility of high-speed dry (HSD) milling of CF/PEEK. However, heat partitioning and jet heat transfer mechanisms pose strong challenges for temperature suppression analytical modeling. To address this gap, an innovative temperature suppression analytical model based on heat partitioning and jet heat transfer mechanisms is first developed for suppressing workpiece temperature via the first-time implementation of an air jet cooling process in the HSD milling of UD-CF/PEEK. Then, verification experiments of the HSD milling of UD-CF/PEEK with four fiber orientations are performed for dry and air jet cooling conditions. The chip morphologies are characterized to reveal the formation mechanism and heat-carrying capacity of the chip. The milling force model can obtain the force coefficients and the total cutting heat. The workpiece temperature increase model is validated to elucidate the machined surface temperature evolution and heat partition characteristics. On this basis, an analytical model is verified to predict the workpiece temperature of air jet cooling HSD milled with UD-CF/PEEK with a prediction accuracy greater than 90%. Compared with those under dry conditions, the machined surface temperatures for the four fiber orientations decreased by 30%–50% and were suppressed within the Tg range under air jet cooling conditions, resulting in better surface quality. This work describes a feasible process for the HSD milling of CF/PEEK. [ABSTRACT FROM AUTHOR]

Metal-based additive manufacturing (AM) displayed a revolutionary influence in the world of engineering and opened the doors to new opportunities for individuals as well as for industries. The design flexibility and high mechanical performance make this process more widespread and popular. Furthermore, the usage of minimal material with less wastage and the lowering of tooling expenses stands out as noteworthy benefits of the AM process. Nonetheless, an inherent limitation of AM printed materials includes issues related to the unique microstructure of AM parts, such as varying material densities, anisotropic properties and residual stresses. These factors can lead to unpredictable tool wear, poor surface finish and dimensional inaccuracies during machining operations. Additionally, the presence of hard inclusions or defects within the printed material can further exacerbate tool wear and increase machining difficulty. As a result, machining processes are often required to obtain the desired surface quality of the component. This study undertook a comprehensive and systematic review of the machinability of metal additive manufactured (AMed) components, contrasting them with wrought materials based on their response parameters. It investigated the turning, milling and drilling performances of AMed components, examining factors such as cutting forces, tool morphology, chip formation, hole quality, surface integrity, tool wear and temperature. This analysis encompassed diverse cutting conditions, building orientations and machining environments including flood, MQL, cryogenic cooling as well as AM parameters and post-heat treatments. Furthermore, this study places a significant emphasis on the sustainable attributes of the cutting fluids utilized in the machining of AM parts, alongside the overall sustainability of the manufactured components. It aims to pinpoint pivotal research findings and constraints while proposing avenues for future research endeavors. The main goal of this review is to furnish a comprehensive resource that consolidates knowledge regarding the surface quality and machinability of AMed metallic objects. Furthermore, it offers suggestions on machining strategies and insights into challenges and potentials related to machining AM parts. Additionally, it provides recommendations to enhance their machinability. Finally, the article introduces potential directions for future research to advance the field and enhance the efficacy of the AMed part. [ABSTRACT FROM AUTHOR]

Pin fin-interconnected reentrant microchannels (PFIRM) of microchannel heat sink cooling systems provide a promising solution for efficient heat dissipation of high heat flux devices. They feature interconnected Ω-shaped reentrant configurations in cross-section, with large circular cavities at the bottom and diamond pin fins at the top. In this paper, a micro ball-end milling process was proposed to fabricate PFIRM. The burr formation process and deformation mechanisms during the micromilling process of PFIRM were investigated with experiments and finite element (FE) simulations. Results revealed that the burrs were mainly formed under the vertex of diamond pin fins on both up-milling and down-milling sides. The burrs on the up-milling side were pushed by the tool neck to the left side of feed direction, whereas the burrs on the down-milling side were thrusted by the flank face to the right side of feed direction. Besides, two unique types of chips, i.e., swallowtail-shaped chips and half swallowtail-shaped chips, were found to be formed during the micro ball-end milling process. Moreover, the effects of spindle speed and feed rate on the machining accuracy and surface roughness of PFIRM were also explored. The machining accuracy and surface roughness firstly increased and then decreased with increasing spindle speed. As the feed rate increased, the machining accuracy decreased in general, and the surface roughness firstly decreased and then increased. The present study suggested that the spindle speed of 15000 r/min and feed rate of 20 mm/min was optimal to improve the surface quality and machining accuracy. • Manuscript's Highlights. • Micro ball-end milling process was developed to fabricate pin fin-interconnected reentrant microchannels (PFIRM). • Burr formation process and deformation mechanisms of PFIRM were explored. • Swallowtail-shaped chips and half swallowtail-shaped chips were formed. • Effects of spindle speed and feed rate on machining accuracy and surface roughness of PFIRM were studied. [ABSTRACT FROM AUTHOR]

Information technology applications are crucial to the proper utilization of manufacturing equipment in the new industrial age, i.e., Industry 4.0. There are certain fundamental conditions that users must meet to adapt the manufacturing processes to Industry 4.0. For this, as in the past, there is a major need for modeling and simulation tools in this industrial age. In the creation of industry-driven predictive models for machining processes, substantial progress has recently been made. This paper includes a comprehensive review of predictive performance models for machining (particularly analytical models), as well as a list of existing models' strengths and drawbacks. It contains a review of available modeling tools, as well as their usability and/or limits in the monitoring of industrial machining operations. The goal of process models is to forecast principal variables such as stress, strain, force, and temperature. These factors, however, should be connected to performance outcomes, i.e., product quality and manufacturing efficiency, to be valuable to the industry (dimensional accuracy, surface quality, surface integrity, tool life, energy consumption, etc.). Industry adoption of cutting models depends on a model's ability to make this connection and predict the performance of process outputs. Therefore, this review article organizes and summarizes a variety of critical research themes connected to well-established analytical models for machining processes. [ABSTRACT FROM AUTHOR]

To distinguish the grinding performance of the multidirectional (MD) and unidirectional (UD) carbon fiber‐reinforced thermoplastic (CFRTP) composites, MD and UD carbon fiber‐reinforced poly‐etherether‐ketone (CF/PEEK) composites were employed in this study. Different ply stacking sequences and process parameters were set for grinding experiments. Subsequently, the surface morphologies and roughness were observed and measured. Experimental results indicated that the variations of grinding forces with grinding parameters of MD‐CF/PEEK and UD‐CF/PEEK were consistent. However, the heat transfer mechanism and the effects of grinding parameters on the maximum grinding temperatures were different between the two composites. The grinding forces and temperatures of MD‐CF/PEEK were slightly lower than UD‐CF/PEEK, and MD‐CF/PEEK reached better surface quality under the same parameters, indicating that the grinding performance of MD‐CF/PEEK was not the simple superposition of UD‐CF/PEEK. In addition, the chip formation and material removal mechanism of CF/PEEK were investigated. The grinding performance of MD‐CF/PEEK was primarily dependent on the θ elements of laminate while the grinding performance of UD‐CF/PEEK was closely related to the fiber orientation angles during grinding. This study established a more in‐depth understanding into the grinding performance of MD‐CF/PEEK and provided technical guidance for high‐quality grinding of CFRTP. Highlights: The grinding performance of the multidirectional (MD) and unidirectional (UD) carbon fiber‐reinforced poly‐etherether‐ketone (CF/PEEK) is compared.The grinding forces and temperatures of MD‐CF/PEEK are slightly lower than that of UD‐CF/PEEK, and the MD‐CF/PEEK reach a better surface quality under the same grinding parameters.The grinding performance of MD‐CF/PEEK is primarily dependent on the θ elements of laminate, and the change of layering order is not a critical factor.The grinding performance of UD‐CF/PEEK is closely related to the fiber orientation angles during the grinding process.The surface quality of MD‐CFRTP can be effectively improved by reducing the grinding depth and feed speed, and increasing the grinding wheel speed. [ABSTRACT FROM AUTHOR]

The present work aims to provide the readers with a bird's-eye view of the general domain of cylindrical gear manufacturing technologies, including the cutting tools used, and related topics. The main scientific sources are explored to collect data about the subject. A systematization of the scientific works is completed, to emphasize the main issues the researchers have focused on in the past years in the domain. Several specific aspects are investigated: chip-forming process, cutting tool lifetime, the materials used to produce gear hobs, temperature and lubrication, the cutting tool geometry, cutting parameters, design methods, and optimization. Some gaps in the research have been identified, which are mainly related to the gear hob's design. These gaps, the organization of knowledge, the current requirements of the industry, and the actual socio-economic priorities form the basis for identifying new scientific research directions for the future in the area of spur gears manufacturing technologies and cutting tools. The main output of this work is a frame to guide the development of scientific research in the domain of spur gear production. [ABSTRACT FROM AUTHOR]

The production of fines and chips during rock cutting plays an essential role in the efficiency of rock cutting, which in turn impacts productivity and performance of mechanical excavators. In this study, small scale linear rock cutting experiments were conducted using a conical tool on thirteen sedimentary and metamorphic rock samples to evaluate the transition between ductile to brittle cutting mode by examining the volume of fines versus chips produced in the process of cutting. Cuts with depths of 0.5, 0.8, 1, 2, 3, 4, 5, and 6 mm were made to investigate the production of fines and chips in unrelieved cutting mode. The forces acting on the conical tool, cutting rate, and volume of fines were measured. Initially, the critical cutting depth was determined by analyzing the cutting force signals, aiming to identify both ductile and brittle cutting failure zones. Subsequently, the percentage of fines were classified into three classes using the hierarchical clustering algorithm. Finally, the support vector machine algorithm was employed to create a two-dimensional space utilizing cutting parameters, enabling the identification of the fines to chip transition zone. The effective cutting depth was determined based on specific energy variations, and subsequently, the effective limit was determined in the fines transition zone. The results showed that cutting depths lower than the critical value lead to the production of high fines under ductile failure mode. Also, the results obtained from assessing the performance of the two-dimensional fines space, predicated on cutting parameters, demonstrated that the developed model effectively evaluates the fines transition zone with a high level of accuracy. The results of this study can help in managing the fines production. [ABSTRACT FROM AUTHOR]

This study investigates the machining processes of Alloy 20 under different cooling conditions: Minimum Quantity Lubrication (MQL), Carbon Dioxide (CO2), and the hybrid MQL + CO2 approach. The research focuses on optimizing the cutting parameters, understanding the surface characteristics, analysing the tool wear patterns, and evaluating the chip formation. Face-centred CCD-based response surface methodology (RSM) is applied in order to identify the optimized cutting conditions. Surface roughness, tool wear, and chip morphology are examined through SEM imaging. Surface roughness characteristics reveal distinctive characteristics for each coolant condition: MQL cooling results in a relatively rough surface with tool nose degradation, CO2 cooling shows scratches on the surface and tool chipping, and MQL + CO2 cooling yields a smoother finish with close and continuous chip formation under the optimized conditions. This study contributes valuable insights into the complex interactions between cutting parameters and coolants, aiding in the optimization of machining processes for improved outcomes of the machining of Alloy 20. Based on the RSM outcomes, the optimal parametric settings obtained are Vc = 44 m/min, f = 0.04 mm/rev, and ap = 0.43 mm. [ABSTRACT FROM AUTHOR]

To improve the machinability properties of CuZn-alloys, these are alloyed with the element lead. Due to its toxicity, a variety of legislative initiatives aim to reduce the lead content in CuZn-alloys, which results in critical machinability problems and a reduction in the productivity of machining processes. Basically, there are two ways to solve the critical machinability problems when machining lead-free CuZn-alloys: optimizing the machinability of lead-free materials on the material side or adapting the processes and the respective process parameters. In this study, the focus is on material-side machinability optimization by investigating the influence of a targeted variation in the process chain in the material production route. To evaluate the influence of the material production route, the brass alloy CuZn40 (CW509L) was produced in four variants by varying the degree of work hardening and the use of heat treatments, and all four variants were evaluated in terms of their machinability. To evaluate the machinability, the cutting force components, the chip temperature, the chip formation, and the chip shape were analyzed. Clear influences of the material production route were identified, particularly with regard to the chip formation mechanisms and the resulting chip shape. [ABSTRACT FROM AUTHOR]

Machinability is a generalized framework that attempts to quantify the response of a workpiece material to mechanical cutting, which has been developed as one of the key factors that drive the final selection of cutting parameters, tools, and coolant applications. Over the years, there are many attempts have been made to develop a standard evaluation method of machinability. However, due to the complexity of the influence factors, i.e., from work material and cutting tool to machine tool, that can affect the materials machinability, currently there is no uniquely defined quantification of machinability. As one of the outcomes from the CIRP's Collaborative Working Group on "Integrated Machining Performance for Assessment of Cutting Tools (IMPACT)", this paper conducts an extensive study to learn interacting machinability parameters to evaluate the overall machining performance. Specifically, attention is focused on recent advances made towards the determination of the machinability through tool wear, cutting force and temperature, chip form and breakability, as well as the surface integrity. Furthermore, the advanced methods that have been developed over the years to enable the improvement of machinability have been reviewed. [ABSTRACT FROM AUTHOR]

Modeling of metal cutting using finite element (FE) method has been investigated in many studies. They make it possible to better understand the chip formation. However, the mesh dependence of the numerical solution is still unsolved. The purpose of this paper is the modeling and simulation of saw-toothed chip formation during high-speed orthogonal cutting. Further, the influences of mesh parameters on saw-toothed chip formation are investigated as an innovative highlight of this study. The investigation of high-speed cutting (HSC) is based on FE analysis, where the Johnson-Cook (JC) constitutive model is combined with an energy-based fracture criterion. The mesh parameters considered include element dimension, element orientation, and hourglass treatment. The results show that the peak and valley values of saw-toothed chip obtained through the model mesh 10 × 10 are close to the measurements, but the pitch value is predicted with a larger error than those of peak and valley values. Square elements of dimension 10 μm can be also used to avoid the influence of element orientation on cutting forces with an error about 10%. When using square elements, the hourglass treatment causes slightly differences in chip morphology and cutting force. On the other hand, the enhanced is the more efficient method to prevent the hourglass effect for rectangular elements. The model mesh 8 × 10 gives an error less than 15% for cutting force. Moreover, the effect of element dimension on cutting force can be reduced by applying the fracture energy criterion controlled through a characteristic length to different mesh dimensions. [ABSTRACT FROM AUTHOR]

In the present work, peripheral milling of CMSX-4 has been carried out at different machining conditions. Three levels of cutting velocity, feed rate and axial depth of cut have been selected to analyse the cutting forces and surface roughness during machining of CMSX-4. Full-factorial design (L27) has been considered for the machining. Furthermore, the analysis of variance has been carried out to find out the most influencing machining process parameters, which affect the cutting force and the surface roughness. The feed rate and depth of cut have been found to be the most influencing process conditions affecting the cutting force while cutting velocity and feed rate have been found to affect the surface roughness. A cross interaction between the machining process parameters has also been found to affect both cutting force and surface roughness during machining. The chip formation analysis has been carried out to analyse the effect of process parameters on the severity of localised shearing induced during the machining process. An increase in spindle speed beyond 3000 rpm has been found to be facilitating the formation of segmented chip. A segmented chip has also been formed at the combination of high feed rate and axial depth of cut. The low feed rate up to 0.04 mm/flute and axial depth of cut up to 0.1 mm accelerate the formation of continuous chip. [ABSTRACT FROM AUTHOR]

In this study, mahogany seed oil was sourced and prepared, and the performances were compared with mineral oils. The extracted oil was characterized to recognize properties related to pyto-chemical, physio-chemical lubricity and thereafter used along with mineral oil for the formulation of cutting fluid using emulsifying agent, anti-corrosive agent, biocides, and anti-foam agent as additives. These additives were added to oil and water by using 24 full factorial design to achieve the optimal combination. In addition, central composite design (CCD) was adopted for the experimental design, and the performance of the mahogany oil-based cutting fluid (MBCF) was investigated in terms of surface finish, cutting temperature, material removal rate, machine sound level, and chips formation and, thereafter, compared with conventional mineral oil (CBCF) in turning of AISI 304 steel under flood cooling technique. Experimental data were analyzed using analysis of variance (ANOVA) and grey relational analysis (GRA). The experimental findings showed that optimal multi-response performance of the MBCF can be achieved using spindle speed, feed rate and depth of cut of 1100 rev/min, 0.27 mm/rev, and 0.23 mm, respectively, while optimal multi-response performance of CBCF can be achieved with spindle speed, feed rate, and depth of cut of 900 rev/min, 0.62 mm/rev, and 0.23 mm, respectively. [ABSTRACT FROM AUTHOR]

Purpose: In modern industry, titanium is recognised for its remarkable wear resistance and strength. However, its poor thermal conductivity poses a problem because it shortens the life cycle of cutting tools. Researchers have focused on enhancing the service life of cutting-edge tools, cutting production costs by using new coating materials, and identifying appropriate materials for these coatings. Design/methodology/approach: The experimental design involved tests with controlled cutting speeds of 150, 175, 200, and 225 m/min, feed rates of 0.2, 0.25, and 0.30 mm/rev, and cutting depths of 0.5, 1.0, and 1.2 mm. Titanium with a diameter of 25 mm and a length of 200 mm was prepared for the turning test over a machining distance of 20 mm. The chips obtained from the cutting test were observed and analysed using a scanning electron microscope to investigate the effect of the tool coating on the characteristics of the chip formation mechanism. Findings: The study revealed that inserts coated with AlCrSiTiN produced the characteristic of long twisted chips transitioning into continuous chips with shorter twisting distances than uncoated cermet inserts. The uncoated cermet inserts resulted in a greater twisting distance based on an examination of the chips with a scanning electron microscope, revealing more pronounced jaggedness in the fragments produced by the cermet turning inserts, which also possessed a larger average clearance than the inserts coated with AlCrSiTiN and TiAlSiN. Furthermore, the uncoated cermet inserts showed less wear at lower cutting speeds than the other types of inserts. Conversely, the TiAlSiN-coated inserts exhibited less wear at higher cutting speeds than the inserts of different materials. Research limitations/implications: The triangularly shaped inserts were cermet inserts coated with AlCrSiTiN or TiAlSiN via the PVD method and were used for dry turning. Practical implications: Wear of cutting-edge tools is a problem in turning of titanium. Therefore, it is crucial to identify methods to minimise wear and extend the service life considering the investment worthiness. Likewise, efforts are being made to develop new coatings tailored to the materials. Originality/value: The research could provide guidelines for reducing the wear generated in cutting tools and increasing the service life of cutting edges by adjusting the machining parameters. [ABSTRACT FROM AUTHOR]

Titanium alloys are widely used in various fields because of their high strength, excellent corrosion resistance, and high heat resistance. As a new advanced titanium alloy for aviation, TC21 titanium alloy has high strength and poor machinability. It is of great significance to study the cutting mechanism of this alloy and the methods to improve the machinability of aircraft. In this paper, aiming at the difficult machinability of titanium alloy TC21, EPH online heating assisted cutting method is put forward for the first time. During the cutting experiment, the TC21 alloy sample was heated to a variety of temperatures through the electric pulse thermal heat technique. Chip shape and cutting force under different heating temperatures were obtained by cutting experiments. In order to study the influence of the heat-assisted cutting process on the machining of TC21 alloy, the orthogonal finite element model was proposed to simulate the heat-assisted cutting process of TC21 alloy. Through this simulation, chip formation, cutting force, and cutting temperature variation were all obtained. The chip formed by the simulation was in accordance with the actual chip. The results demonstrate that the influence of heat-assisted machining on chip morphology of titanium alloy is relatively small, but it has a significant influence on cutting force and surface roughness. The results show that when the sample is heated to 600°C, the surface quality is the best and cutting force can be reduced by more than 40%. [ABSTRACT FROM AUTHOR]

Although chip morphology changes according to the machining method and related cutting parameters, chip formation affects the quality of the machined surface. In this context, it is very important to understand the relationship between chip morphology and surface quality, especially in materials that are difficult to machine. In the presented study, the changes in chip morphology, surface morphology, and surface quality criteria (Ra and Rz) that occurred during the milling of precipitation-hardened steel in different cutting environments were analyzed. Milling experiments were carried out in dry, MQL (minimum quantity lubrication), nano-MQL (graphene), nano-MQL (hBN), Cryo, and Cryo-MQL environments using TiAlN-coated inserts and three different cutting speeds and feed rates. While the highest values in terms of Ra and Rz were measured in dry machining, the minimum values were obtained in a nano-MQL (hBN) cutting environment. Due to the lubrication and low friction provided by the MQL cutting environment, chips were formed in thinner segmented forms. This formation reduced the chip curve radius and thus provided a more stable surface morphology. On the other hand, Cryo-ambient gas could not effectively leak into the cutting zone due to the intermittent cutting process, but it increased the brittleness of the chips with the cooling effect and provided a similar surface morphology. The values of minimum Ra and Rz were obtained as 0.304 mm and 1.825 mm, respectively, at a 60 m/min cutting speed and 0.04 mm/rev feed. Consequently, the use of nano-MQL cutting medium is seriously recommended in terms of surface quality in milling operations of difficult-to-machine materials. [ABSTRACT FROM AUTHOR]

Ti 2 AlNb intermetallic, as a relatively new high temperature-resistant structural material, belongs to typical difficult-to-machine material due to its excellent mechanical properties. This paper aims to investigate the dynamic deformation behavior in chip shear deformation zone and associated chip formation mechanism during the machining of Ti 2 AlNb intermetallic. A specialized cutting platform combined with a high speed imaging system is developed to realize in-situ detection of full field deformation and corresponding signal processing during the machining process. The high speed imaging system can capture in-situ material deformation images with a frequency of 100 kHz during cutting process while the digital image correlation method is adopted to characterize chip dynamic deformation signals quantitatively. A series of orthogonal cutting experiments for Ti 2 AlNb is conducted at different cutting depths and cutting speeds, based on which the influences of cutting parameters on chip morphologies and material removal process are studied. The distribution of material flowing velocity, as well as the strain rate fields within shear deformation zone in chip removal process of Ti 2 AlNb are analyzed. Finally, the formation mechanism of periodic built-up edge formed in the cutting speed range of 60–120 m·min−1 is elucidated. • Kinematic field of T i2 AlNb chip formation are in-situ detected and characterized. • Strain rate distribution during the formation of different types of chips is studied. • Chips morphology evolution of Ti 2 AlNb at varied cutting parameters is studied. • Formation mechanism of periodic built-up edges is analyzed with DIC method. [ABSTRACT FROM AUTHOR]

Objectives: In unattended machining, monitoring the cutting processes holds significant importance. A crucial aspect to consider is whether chip formation occurs at a specific moment or not. Acquiring this knowledge can enhance production reliability and minimize losses. Methods: To address this, an algorithm is proposed for detecting chip formation using vibration signals obtained from a CNC machine. The algorithm relies on the spindle RPM and vibration signal to identify the occurrence of machining cycles (chip formations). The evaluation process involved comparing the results of the algorithm to those obtained by a human manually selecting the machining parts from the same signal. Results: Its effectiveness was evaluated across various feedrates, demonstrating its applicability under different conditions. Conclusions: This method is able to detect the real machining more accurate than the use of G-code-based method. [ABSTRACT FROM AUTHOR]

Micro-cutting is characterised by undeformed chip thicknesses in the micron range. This range leaves little choice of in situ observation techniques. One solution is therefore to observe these zones a posteriori after the cutting has been abruptly interrupted. This technique has proven to be very useful for conventional machining. This paper deals with the development of a quick-stop device dedicated to micro-cutting. The aim of this device is to observe cutting mechanisms and chip formation at this scale in order to enhance micro-cutting models. [ABSTRACT FROM AUTHOR]

Orthogonal cutting on Ti-6Al-4V produces segmented chips which results from localized deformation within the Primary Shear Zone (PSZ). For in situ visualization of the material flow during Ti-6Al-4V chip formation, a new high-speed optical system is proposed. Difficulties arise from the submillimetric size of the cutting zone. Therefore, a dedicated optical system with coaxial illumination is designed allowing for local scale analysis of chip formation. In this paper, the cutting forces were measured highlighting the unsteady nature of Ti-6Al-4V chip segmentation. For kinematic fields measurement, a novel method of Digital Image Correlation (DIC) technique is applied on the recorded images from the cutting zone. It allows for the identification of the localized deformation bands. Then, the level of the cumulative strain fields reached in the PSZ was presented and analyzed. The effect of the rake angle on the strain fields was studied. Using a 0∘ rake angle, the segment chip was found to be more subjected to deformation than in the case using 15∘. Accuracy of the measured strain fields was discussed function of the main source of errors. In addition, the chip morphology and microstructure were investigated with a scanning electron microscopy (SEM). It shows crack opening along the PSZ and high material failure near the tool-chip interface which explains the difficulties of DIC application in the context of kinematic fields measurement during orthogonal cutting. Finally, correlation between the measured strain fields and the mean value of the chip segment width was made. [ABSTRACT FROM AUTHOR]

In this paper, further in-depth research on chip formation mechanism is conducted on the cutting of metallic glasses. The study of chips contributes to a better understanding of the machining nature of materials, which is of significant importance for improving product quality, reducing energy consumption, and resource utilization. This paper employs a combination of simulation and experimental methods, wihch not only analyzes the mechanism of chip formation in depth, but also investigates the time-varying characteristics of cutting forces. The results indicate that, when comparing simulation with experiments, the average error in cutting forces is 7.62%, and the chip morphology is also quite similar. Observations in the simulation show that as the cutting thickness increases from 7.96 μm to 23.87 μm, the free surface of the chip exhibits serrated features, and the main shear zone of the chip becomes clearer. Cutting forces exhibit periodic variations, with alternating peaks and valleys representing the formation of shear zones in the chip. In the experiment, observed chips displays a wrinkled free surface and a smooth non-free surface, with some chip edges exhibiting a burr phenomenon. By selecting appropriate machining parameters, the generation of secondary shear bands on the free surface was effectively reduced. By observing the chip morphology, it is found that the chip formation is accompanied by the material removal of plasticity and brittleness, which is the result of the combined action of heat, stress, and free volume. It should be considered to lower temperature to reduce the phenomenon of chip adhesion, providing guidance for further optimizing the cutting process of metallic glass. This paper can provide to readers further understanding of the chip formation mechanism in milling metal glass. • 2D finite element modeling was used to simulate the chip formation. • The shear zones appeared on the serrated chips. • The experimental results verified the accuracy of the simulation model. • The chips of BMG have smooth non-free surface and wrinkled free surface. • The serrated chips are the result of heat, stress, and free volume. [ABSTRACT FROM AUTHOR]

The demand for Ni-based alloys, particularly Alloy 718, is increasing in the gas turbine industry due to their high-temperature resistance and chemical stability. However, Alloy 718 is challenging to cut, owing to its susceptibility to work-harden, its high cutting resistance, and its poor thermal conductivity. Ultrasonic elliptical vibration cutting (UEVC) can be performed on steel materials using diamond tools, which is facilitated by elliptical vibration of the tool. This approach helps suppress heat generation at the tool tip and prevents chemical decomposition. In this study, we explored the precision cutting of Alloy 718 using UEVC with planar cutting and a single-crystal diamond flat tool. We achieved a surface roughness Ra of 8.4 nm at a cutting speed of 2.0 mm/s. We compared surface roughness under various conditions, including cutting speeds, the amplitude of elliptical vibration, and cutting depth, to investigate the effect of these parameters on surface roughness. Additionally, we studied the geometry and thickness of chips under these conditions using scanning electron microscopy (SEM) images. Our findings indicated flow-type chip shapes in all conditions, signifying stable ductile-regime cutting. Moreover, tool life was investigated by observing the cutting edge, which exhibited slight wear, maintaining a mirror surface for a cutting distance of approximately 50 m. These findings reveal an effective method for high-precision surface fabrication of Alloy 718, elucidating the cutting mechanism and the feasible cutting distance.

Machining of bone tissue is a significant procedure in many surgical interventions. Due to the limited research on this topic, understanding the processes occurring during bone processing is crucial for designing tools that optimize the surgical process. This paper presents a model of machining cortical bone with a negative rake angle tool based on three cutting modes. The model was prepared based on experimental data from the orthogonal cutting of cortical bone tissue, numerical simulations, and theoretical models considering the presence of the stagnation zone. Special attention was given to the influence of bone anisotropy on chip formation, chip morphology, and the type and propagation of cracks depending on the orientation of osteons relative to the cutting edge. The analysis of crack morphology and chip structure revealed the mechanisms involved in the material's destruction, which were incorporated into the prepared model. The experimental results confirm the consistency with the proposed model. Based on the prepared cutting model, it is possible to determine the threshold depths of cutting that allow for controlled processing of bone surfaces, predicting the milling machine and the type of formed chips. The model developed based on experimental data is the first for cortical bone tissue. This analysis holds significant theoretical and practical importance for developing innovative orthopedic tools and surgical methods. [ABSTRACT FROM AUTHOR]

In modern times, titanium alloy has a great application prospect in the medical field. Still, the pitiful machinability of titanium alloy material brings incredible difficulty to its ultra-precision cutting. This work presented the effect of parametric sensitivity analysis of the orthogonal cutting process using the finite element method, which dramatically enhances the cutting performance of Ti–6AL–4V. The simulation results are attained by applying Abaqus® explicit 6.14 software. The mechanical reaction of two-dimensional finite element models has been examined for cutting forces. Additionally, the impacts of rake angle, clearance angle, and nose radius on the stress distribution in orthogonal cutting of Ti–6AL–4V have been investigated. Also, to make certain numerical accuracy, the Johnson–Cook constitutive models for Ti6Al4V alloy are implemented. In the end, FE simulation outcomes were supported by the reported results in the literature. [ABSTRACT FROM AUTHOR]

Chip formation is dependent on the machining environment and is a major factor representing machining characteristics. This paper experimentally investigates the influence of cryogenic cooling and minimum quantity lubrication (MQL) on chip formation during titanium milling and their effects on tool wear and cutting force. Chip segmentation, shear angle, grain size, and compositions were evaluated according to the tool wear evolution. An application of cryoMQL strategy, which means the use of cryogenic cooling and MQL simultaneously, delayed the time of chip serration; serrated chips appeared at long machining distances compared to the dry machining. Then, the cryoMQL machining increased the shear angle and decreased grain size and oxygen atomic percentage. The phenomena represented occurrences of effective cooling and lubrication and reduced the tool flank wear length and the resultant force by 56.5% and 13.5%, respectively, compared to dry condition. The improvement in machinability was more remarkable in the cryoMQL condition than in the condition where cryogenic cooling and MQL were separately applied. [ABSTRACT FROM AUTHOR]

The article assesses the effectiveness of turning polymeric materials with ceramic cutting tools. It is experimentally proven that turning caprolon and fluoropolymer using a cutting tool insert made of KNT16 cermet results in higher quality of the machined surface. The roughness parameters of a surface machined with a cermet cutting insert are lower than when turning with an insert made of VK8 tungsten–cobalt alloy, and the chips formed are of a different type. [ABSTRACT FROM AUTHOR]

The article considers aspects of leather waste processing aimed at using dispersed waste for creating composite materials of various purposes. It is shown that a reduction in the relaxation and creep of the material is achieved by increasing the cutting speed. The proposed method of dimensional dispersion uses a claw-shaped impact cutting tool, the complex movement of which is powered by a high-frequency vibration motor. A model of the process of leather waste dispersion is developed in the LSTC LS-Dyna software for continuum mechanics modeling. [ABSTRACT FROM AUTHOR]

Vanadis 4E is a versatile powder metallurgical tool steel widely used in today's market with high wear resistance and excellent yield properties. Drilling operations applied to materials are one of the operations commonly used in the machining industry. In drilling operations, coated or uncoated drills are used, which may vary according to the material used. This study applied drilling operation to Vanadis 4E powder metallurgical steel with TiN-coated HSS drills. In the study, Drills with diameters of 5, 8.5, and 10.5 mm, cutting speeds of 22, 23, and 24 m/min, and feed rates of 0.10, 0.12, and 0.14 mm/tooth was used. Nine experiments were carried out using the Taguchi L9 orthogonal array. After the experiments, the material was cut from the holes, and the roughness values were measured from the inner surfaces of the holes. In addition, hardness measurements were made from the material surfaces around the holes. The wear conditions of the drills used in the experiments were examined with an optical microscope after the experiment. The formations after each experiment were also examined. The best roughness value was obtained with the 5 mm diameter drill in the 1st experiment, the best roughness value was obtained in the experiments carried out with the 8.5 mm diameter drill in the 6th experiment, and the best roughness value was obtained in the 7th experiment for the 10.5 mm diameter drill. When the wear in the drills was evaluated, it was observed that the side surface and radial wear occurred.

The present work aims to provide the readers with a bird’s-eye view of the general domain of cylindrical gear manufacturing technologies, including the cutting tools used, and related topics. The main scientific sources are explored to collect data about the subject. A systematization of the scientific works is completed, to emphasize the main issues the researchers have focused on in the past years in the domain. Several specific aspects are investigated: chip-forming process, cutting tool lifetime, the materials used to produce gear hobs, temperature and lubrication, the cutting tool geometry, cutting parameters, design methods, and optimization. Some gaps in the research have been identified, which are mainly related to the gear hob’s design. These gaps, the organization of knowledge, the current requirements of the industry, and the actual socio-economic priorities form the basis for identifying new scientific research directions for the future in the area of spur gears manufacturing technologies and cutting tools. The main output of this work is a frame to guide the development of scientific research in the domain of spur gear production.

To improve the machinability properties of CuZn-alloys, these are alloyed with the element lead. Due to its toxicity, a variety of legislative initiatives aim to reduce the lead content in CuZn-alloys, which results in critical machinability problems and a reduction in the productivity of machining processes. Basically, there are two ways to solve the critical machinability problems when machining lead-free CuZn-alloys: optimizing the machinability of lead-free materials on the material side or adapting the processes and the respective process parameters. In this study, the focus is on material-side machinability optimization by investigating the influence of a targeted variation in the process chain in the material production route. To evaluate the influence of the material production route, the brass alloy CuZn40 (CW509L) was produced in four variants by varying the degree of work hardening and the use of heat treatments, and all four variants were evaluated in terms of their machinability. To evaluate the machinability, the cutting force components, the chip temperature, the chip formation, and the chip shape were analyzed. Clear influences of the material production route were identified, particularly with regard to the chip formation mechanisms and the resulting chip shape.

Primary manufacturing processes like casting, forming, and shaping (forging, rolling, drawing, extrusion, sheet forming, and molding) further need any of the secondary manufacturing processes like turning, drilling, boring, planing, milling, grinding, etc. In order to produce superior quality products, and to enhance productivity, the selection of desirable process parameters is significant. The selection of suitable process parameters is essential for accomplishing the desired component. Based on the existing literature, this study examines the causes, effects, and variances regarding chip formation, tool geometry, thrust force, torque, surface roughness, drilling time, and other drilling quality characteristics in the most typical machining operations such as drilling. Developing a repository on these process parameters will guide the process planning engineer for ready reckon. Therefore, this work aims at the development of a detailed repository with the study of characteristics. Further, this literature review comprehends the characteristics of a behavior with its reasoning, which was detailed in the past decade. It reveals the beneficial process parameters for achieving better production rate and superior quality. [ABSTRACT FROM AUTHOR]

Titanium and titanium alloys have high specific strength, excellent corrosion resistance and excellent biocompatibility. Therefore, the use of titanium materials is widespread in high-performance applications such as aerospace and biomedical industries. However, titanium and titanium alloys such as Ti-6Al-4V are considered as difficult to machine. This is attributed to their low thermal conductivity, unfavourable chip formation with typically segmented chips, and high thermomechanical load on the cutting tool. In addition, titanium alloys have a high chemical affinity for surrounding elements such as oxygen. Tool wear, surface and subsurface properties of the workpiece are significantly affected by the presence of oxygen and the resulting chemical interactions. Among other things, chemical reactions such as oxidation occur due to the high temperatures and presence of oxygen. In this work, the chip formation of Ti-6Al-4V at different cutting speeds in continuous orthogonal cutting under different atmospheres is investigated. A conventional air atmosphere, a pure argon atmosphere and a silane-doped argon atmosphere were used. The oxygen content of the silane-doped argon atmosphere corresponds to an extremely high vacuum (XHV), which is practically oxygen-free. It was found that by using an XHV-adequate atmosphere, a significant reduction in chip segmentation occurs. In addition, the feed force is up to 26% lower under silane-doped argon atmosphere compared to cutting under air. This can be attributed to up to 23% reduced coefficient of friction in the secondary shear zone. In addition, the maximum tool temperature at a cutting speed of v c = 60 m/min was reduced by up to 310 °C as a result of using an XHV-adequate atmosphere. [ABSTRACT FROM AUTHOR]

Copyright of Duzce University Journal of Science & Technology is the property of Duzce University Journal of Science & Technology and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

This study introduces a pioneering three-dimensional simulation model for Abaqus multi-grit grinding, developed via Python's secondary capabilities. The model generates random 48-sided abrasive grains arranged on a cylinder following a characteristic distribution pattern, thus emulating a 200-grit micro-abrasive rod. The model considers varying spindle speeds, grinding depths, and feed rates to investigate the influence of multi-grit on the surface profiles of chips and workpieces for the nickel-based single-crystal Superalloy DD5. The multi-grain simulation reveals that grain 1 produces serrated chips at 60 kr/min in 46% of the global process, increasing to 60% at 80 kr/min. Abrasive generation and grinding initiation occur 10% and 12% earlier, respectively, at 100 kr/min compared to 80 kr/min Additionally, peak grinding forces rise with displacement as spindle speed increases. With a feed rate of 2 m/s, serrated chips constitute 36% of the global process in grain 1, increasing to 50% at 3 m/s. At a peak feed rate of 4 m/s, grinding force decreases as displacement increases. The normal distribution of abrasive particles causes an increase in the number of particles involved in grinding as grinding depth grows. This innovative model contributes valuable insights into the complex dynamics of multi-grit grinding processes and optimization strategies. [ABSTRACT FROM AUTHOR]

In the machining of difficult-to-machine metals, such as titanium-based alloys, the delivery of coolant with high pressure can increase machining efficiency and improve process stability through more efficient chip breaking and better cooling. Proper selection of machining conditions can also increase the productivity of the process by reducing cutting forces and tool wear rate. To investigate the effect of high-pressure jet cooling (HPJC) on cutting force, surface roughness, and chip formation of Ti-6Al-4V ELI in high-speed turning, Grade 5 Ti ELI turning tests were carried out under coolant pressure of 200 bar. A lower pressure of 6 bar was also used in this study to compare the results of the pressure change. In general, surface roughness increased as the feed rate increased at constant cutting speeds in experiments with both 6 bar and 200 bar coolant pressures. Even though 200 bar pressure provided a better cooling thus reduced cutting force, and tool wear rate; the surface roughness values ​​obtained from the experiments with 200 bar were relatively worse than the experiments with 6 bar pressure. It was also seen that 200 bar coolant pressure may result in instabilities in the turning process in terms of chip geometries and formations. [ABSTRACT FROM AUTHOR]

Abstract To benefit tissue removal and postoperative rehabilitation, increased efficiency and accuracy and reduced operating force are strongly required in the osteotomy. A novel elliptical vibration cutting (EVC) has been introduced for bone cutting compared with conventional cutting (CC) in this paper. With the assistance of high-speed microscope imaging and the dynamometer, the material removals of cortical bone and their cutting forces from two cutting regimes were recorded and analysed comprehensively, which clearly demonstrated the chip morphology improvement and the average cutting force reduction in the EVC process. It also revealed that the elliptical vibration of the cutting tool could promote fracture propagation along the shear direction. These new findings will be of important theoretical and practical values to apply the innovative EVC process to the surgical procedures of the osteotomy.

Although chip morphology changes according to the machining method and related cutting parameters, chip formation affects the quality of the machined surface. In this context, it is very important to understand the relationship between chip morphology and surface quality, especially in materials that are difficult to machine. In the presented study, the changes in chip morphology, surface morphology, and surface quality criteria (Ra and Rz) that occurred during the milling of precipitation-hardened steel in different cutting environments were analyzed. Milling experiments were carried out in dry, MQL (minimum quantity lubrication), nano-MQL (graphene), nano-MQL (hBN), Cryo, and Cryo-MQL environments using TiAlN-coated inserts and three different cutting speeds and feed rates. While the highest values in terms of Ra and Rz were measured in dry machining, the minimum values were obtained in a nano-MQL (hBN) cutting environment. Due to the lubrication and low friction provided by the MQL cutting environment, chips were formed in thinner segmented forms. This formation reduced the chip curve radius and thus provided a more stable surface morphology. On the other hand, Cryo-ambient gas could not effectively leak into the cutting zone due to the intermittent cutting process, but it increased the brittleness of the chips with the cooling effect and provided a similar surface morphology. The values of minimum Ra and Rz were obtained as 0.304 mm and 1.825 mm, respectively, at a 60 m/min cutting speed and 0.04 mm/rev feed. Consequently, the use of nano-MQL cutting medium is seriously recommended in terms of surface quality in milling operations of difficult-to-machine materials.

In order to distinguish the grinding performance of the thermoset and thermoplastic carbon fiber‐reinforced plastic (CFRP) composites, carbon fiber‐reinforced epoxy resin (CF/epoxy) and carbon fiber‐reinforced poly‐ether‐ether‐ketone (CF/PEEK) composites were employed in this study. Different process parameters were set to grind the two materials. Then the surface morphologies and roughness of the workpieces with different process parameters were observed and measured. Experimental results indicated that the grinding forces were positively correlated with the grinding depth and feed speed, and negatively correlated with the wheel speed. The grinding depth was the main influencing factor of the maximum temperature of the grinding. The heat distribution of the grinding process was dependent on the fiber direction. In addition, the chip formation mechanism of CF/epoxy and CF/PEEK were investigated. Compared with CF/epoxy, the grinding forces and temperature were higher and the wheel was more prone to be clogged under the same grinding parameters, indicating that it was more difficult to process CF/PEEK. However, the surface quality of CF/PEEK with high ductility was much better than CF/epoxy. [ABSTRACT FROM AUTHOR]

Carbon-fibre-reinforced plastic (CFRP) is increasingly being used in various applications including aerospace, automotive, wind energy, sports, and robotics, which makes the precision modelling of its machining operations a critical research area. However, the classic finite element modelling (FEM) approach has limitations in capturing the complexity of machining, particularly with regard to the interaction between the fibre–matrix interface and the cutting edge. To overcome this limitation, a hybrid approach that integrates smoothed particle hydrodynamics (SPHs) with FEM was developed and tested in this study. The hybrid FEM-SPH approach was compared with the classic FEM approach and validated with experimental measurements that took into account the cutting tool's round edge. The results showed that the hybrid FEM-SPH approach outperformed the classic FEM approach in predicting the thrust force and bounce back of CFRP machining due to the integrated cohesive model and the element conversion after failure in the developed approach. The accurate representation of the fibre–matrix interface in the FEM-SPH approach resulted in predicting precise chip formation in terms of direction and morphology. Nonetheless, the computing time of the FEM-SPH approach is higher than the classic FEM. The developed hybrid FEM-SPH model is promising for improving the accuracy of simulation in machining processes, combining the benefits of both techniques. [ABSTRACT FROM AUTHOR]

The cutting characteristics of unidirectional carbon fiber-reinforced plastic (CFRP) during zig-zag milling, which is the most used milling tool path in the industry, were analyzed. Cutting force and chip formation are the most useful indicators of cutting performance. Here, cutting force and chip formation were analyzed in up- and down-milling, then compared with those parameters in zig-zag milling. CFRP cutting force models for up- and down-milling were used for analysis of cutting force. Chip formations were predicted via simulations of fiber cutting angle. This simulation-based study overcame various experimental limitations regarding CFRP cutting force. The specific cutting forces of various fiber cutting angles were derived from cutting experiments involving unidirectional CFRP. The specific cutting forces decreased with increasing chip thickness. These results are similar to the size effect observed in metal machining. Cutting force analysis was performed with a focus on change in feed direction and rate of radial immersion. In zig-zag milling, the optimal feed direction rapidly changed at a radial immersion of 30%. At a radial immersion of 75%, the difference in cutting force related to the change in the feed direction was large. Type I (delamination-type) chip formation was dominant in the optimal feed direction because specific cutting force was lower in the Type I section than in regions of other chip formation types. [ABSTRACT FROM AUTHOR]

This paper investigated the cutting behaviors and chip formation in machining of carbon fiber reinforced polymer (CFRP) composites. The single cutting edge and unidirectional (UD) laminates of six different fiber orientations from 0° to 150° with an interval of 30° were employed in the orthogonal cutting test. The effects of fiber cutting angle, cutting speed and cutting depth on cutting mechanism and micro-damage evolution were estimated. Cutting force and thrust force obtained by dynamometer were used to evaluate the interaction between the tool and the workpiece. Subsurface damage was assessed by damage depth and failure mode of microstructure such as fiber and matrix. The machined surface roughness was used to characterize the machined surface quality. The results indicated that the average cutting force at θ > 90° was 7.58 times higher than that at θ < 90° and large deformed fibers below the machined surface existed elasticity recovery in the former case. The cutting speed and cutting depth had the most significant effects on the cutting force at θ = 90° where the fiber bending deformation and fiber kinking keep cutting force at a high level. The micromorphology of machined surface and subsurface revealed four typical cutting mechanisms, namely, interface-debonding, fracture-sliding, shearing-fracture, and bending-fracture in the range of θ = 0 ~ 180°. The variation trend of surface roughness with cutting parameters at θ > 90° is obvious and in consistent with that of cutting force. The most efficient factor on the roughness is found to be the fiber cutting angle accounting for 98.60%, followed by the cutting depth (0.55%) and cutting speed (0.25%). The interaction between the factors is not significant according to the results of ANOVA. [ABSTRACT FROM AUTHOR]

In this experimental work, the effects of cutting fluid and different cutting parameters on surface roughness, tool wear, and chip morphology during turning of Al7075-T6 were investigated. Machining experiments have been done in different environments such as dry, wet, minimum quantity lubrication (MQL) as well as a homemade ultrasonic nozzle- minimum quantity lubrication (UNMQL). Ultrasonic vibrations can be used to effectively atomize the cutting fluid into fine and uniform-sized droplets and smaller spray angles with a larger spray deposition distance. The MQL system and machining parameters were evaluated by the design of experiments (DOE) method which allows us to carry out the optimization analysis by performing a relatively small number of experiments while determining the influence on the machining performance using the analysis of variance technique. In the second step, an optimization of the machining parameters was sought using signal-to-noise ratio analysis. Therefore, the response surface methodology was determined in a regression analysis, which was used to model the influence of the parameters on the performance. The fine droplets produced by the UN-MQL system penetrate effectively into the machining zone. Finally, the chip morphology, tool wear and surfaces of the machined parts were examined using optical microscopy to identify the chip formation mechanism in different machining conditions. Cutting tool wear were also examined using the SEM tests to quantify the tool wear zones under specific process parameters. Experimental results show that applying UN-MQL system reduces the surface roughness and tool wear by up to 30% in comparison to the conventional MQL system. [ABSTRACT FROM AUTHOR]

Copyright of China Forest Products Industry is the property of China Forest Products Industry Editorial Office and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

SiCp/Al composites are considered as a typical difficult-to-machining material due to the presence of reinforcing particles in the matrix. As the aerospace and military industries demand high dimensional accuracy, high efficiency and low damage for SiCp/Al composites, traditional cutting (TC) methods are no longer sufficient. Ultrasonic elliptical vibration cutting (UEVC) is a cutting technique suitable for difficult-to-machining materials. Its intermittent cutting characteristics can reduce the cutting force, and when the tool cuts the workpiece at ultrasonic frequency, similar to a dynamic impact behavior of the tool on the workpiece with ultrasonic frequency, improve the machinability of the material. In this paper, a multiphase based simulation model is developed that integrates the relationship between three phases and the random distribution of particles. The cutting process of SiCp/Al composites under UEVC and TC is simulated and the removal mechanism of SiCp/Al composites under UEVC is analyzed. The effects of dynamic impact on the UEVC of composites were discussed in terms of chip formation, cutting force and surface morphology. Finally, the correctness of the simulation results was verified by the relevant cutting experiments. The results showed that the UEVC produced more continuous serrations, easier fracture of SiC particles and improved machining performance of SiCp/Al composites compared with the TC. The cutting forces were reduced by 26% and 23%, and the surface roughness was reduced by 19% and 28% at two cutting depths of 25 μm and 50 μm, respectively.