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Ultrasonic Vibration-Assisted Machining Particle-Reinforced Al-Based Metal Matrix Composites—A Review

Year: 2025

Type: article

Abstract: Particle-reinforced Al-based matrix composites have great potential for application in aerospace, automotive manufacturing, and defense due to their high strength, hardness, and excellent wear and corrosion resistance. However, the presence of particles increases the processing difficulty, making it a typical difficult-to-machine material. In recent years, ultrasonic vibration-assisted machining has been quite popular in manufacturing this kind of material. This paper reviews the research advancements in ultrasonic vibration-assisted machining of particle-reinforced Al-based matrix composites, providing a comprehensive analysis of the effects of introducing an ultrasonic energy field on tool wear, chip morphology, cutting force, cutting temperature, and surface integrity. Ultrasonic vibration periodically alters the contact state between the tool and the workpiece, effectively reducing the tool wear rate and extending the tool life. Meanwhile, ultrasonic vibration facilitates the fracture and ejection of chips, enhancing chip morphology and reducing energy consumption during the cutting process. Additionally, ultrasonic vibration significantly decreases cutting force and cutting temperature, contributing to the stability of the cutting process and improving processing efficiency. Regarding surface integrity, ultrasonic vibration-assisted machining refines the machined surface’s microstructure, reducing surface defects and residual stress, thereby significantly enhancing the machining quality. In the future, we will conduct in-depth research on the effects of ultrasonic energy on material properties in terms of softening effect, thermal effect, and stress superposition, further revealing the mechanism of ultrasonic vibration-assisted processing of particle-reinforced aluminum-based composite materials.

Source: Metals

DOI: 10.3390/met15050470

Authors: Xiaofen Liu, Yifeng Xiong, Qingwei Yang

Institutions: Shangluo University, Northwestern Polytechnical University

Language: English

Topic: Advanced machining processes and optimization

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

Open Access status: gold

Estimated APC paid: $3,137

Funders: Shangluo University, Natural Science Basic Research Program of Shaanxi Province