SiCp/Al composites have been widely used in many fields due to their excellent mechanical properties. However, the addition of reinforced phase SiC particles makes the overall properties of the composites hard and brittle, which brings great challenges to milling. Ultrasonic vibration-assisted processing technology has great advantages in processing hard and brittle materials. However, the process of rupture of SiC particles cannot be effectively observed during the test processing, and a large number of tests increase the cost of the test. The combination of finite element analysis and experiment was used to study the machining performance of High-volume fraction SiCp/Al composites in longitudinal-torsional ultrasonic-assisted milling (LTUAM), and its feasibility was evaluated by comparing with conventional Milling (CM). By analyzing the trajectories of cutting edges in ultrasonic-assisted milling, It was found that ultrasonic frequency determines the time of periodic contact-separation between chisel edge and workpiece, and ultrasonic amplitude determines the maximum distance of contact-separation. Using ABAQUS finite element software, a polygon SiC particles model with a high-volume fraction was established to investigate the SiC particles crushing process under different ultrasonic-assisted milling conditions. The results showed that high-frequency ultrasonic-assisted milling could soften SiCp/Al composites, and the structural integrity of silicon carbide particles could be better maintained under appropriate ultrasonic amplitudes, reducing the probability of fragmentation. The removal mode was mainly plastic removal or crushing into small particles. The surface roughness value and milling force were reduced, improving the surface quality of the processed composite material. The conclusions of the milling test were basically consistent with the simulation results, which prove the correctness and feasibility of the simulation results.

SiCp/Al复合材料由于其优异的力学性能而被广泛应用于许多领域。然而，增强相碳化硅颗粒的加入使复合材料的整体性能变硬变脆，给球磨带来了很大的挑战。超声波振动辅助加工技术在加工硬脆材料方面具有很大的优势。但在试验加工过程中无法有效观察到SiC颗粒的破裂过程，大量试验增加了试验成本。采用有限元分析与实验相结合的方法研究了高体积分数SiCp/Al复合材料在纵向扭转超声辅助铣削（LTUAM）中的加工性能，并通过与常规铣削（CM）的对比评估了其可行性。通过分析超声辅助铣削切削刃的轨迹，发现超声频率决定了横刃与工件之间周期性接触分离的时间，超声振幅决定了接触分离的最大距离。利用ABAQUS有限元软件，建立了高体积分数的多边形SiC颗粒模型，研究了不同超声辅助研磨条件下SiC颗粒的破碎过程。结果表明，高频超声辅助铣削可以软化SiCp/Al复合材料，在适当的超声振幅下可以更好地保持碳化硅颗粒的结构完整性，降低碎裂的可能性。去除方式主要是去除塑料或粉碎成小颗粒。降低了表面粗糙度值和铣削力，提高了加工复合材料的表面质量。铣削试验结论与仿真结果基本一致，证明了仿真结果的正确性和可行性。