Ceramic matrix composites of type C/SiC have great potential because of their excellent properties such as high specific strength, high specific rigidity, high-temperature endurance, and superior wear resistance. However, the machining of C/SiC is still challenging to achieve desired efficiency and quality due to their heterogeneous, anisotropic, and varying thermal properties. Rotary ultrasonic machining (RUM) is considered as a highly feasible technology for advanced materials. Cutting force prediction in RUM can help to optimize input variables and reduce processing defects in composite materials. In this research, a mathematical axial cutting force model has been developed based on the indentation fracture theory of material removal mechanism considering penetration trajectory and energy conservation theorem for rotary ultrasonic face milling (RUFM) of C/SiC composites and validated through designed sets of experiments. Experimental results were found to be in good agreement with theoretically simulated results having less than 15% error. Therefore, this theoretical model can be effectively applied to predict the axial cutting forces during RUFM of C/SiC. The surface roughness of the workpiece materials was investigated after machining. The relationships of axial cutting force and surface roughness with cutting parameters, including spindle speed, feed rate, and cutting depth, were also investigated. In order to identify the influence of cutting parameters on the RUFM process, correlation analysis was applied. In addition, response surface methodology was employed to optimize the cutting parameters.

C / SiC型陶瓷基复合材料具有出色的潜力，因为它们具有优异的性能，例如高比强度，高比刚度，高温耐久性和优异的耐磨性。但是，由于C / SiC的异质性，各向异性和变化的热特性，因此对其进行机械加工对于实现所需的效率和质量仍然具有挑战性。旋转超声加工（RUM）被认为是用于先进材料的高度可行的技术。RUM中的切削力预测可以帮助优化输入变量并减少复合材料中的加工缺陷。在这项研究中 基于材料去除机理的压痕断裂理论，考​​虑了C / SiC复合材料的旋转超声面铣削（RUFM）的穿透轨迹和节能定理，建立了数学的轴向切削力模型，并通过设计实验进行了验证。实验结果与理论模拟结果吻合良好，误差小于15％。因此，该理论模型可以有效地应用于预测C / SiC RUFM过程中的轴向切削力。加工后研究工件材料的表面粗糙度。还研究了轴向切削力和表面粗糙度与切削参数（包括主轴转速，进给速度和切削深度）之间的关系。为了确定切削参数对RUFM工艺的影响，应用了相关分析。另外，采用响应面方法来优化切削参数。