Influence of process parameters on surface topography in ultrasonic vibration- assisted end grinding of SiCp/Al composites

The surface quality in ultrasonic vibration-assisted end grinding of SiCp/Al composites is important as it influences the performance of the finished surface to a great extent. This paper presents a comprehensive analysis to characterize the machined surface topography with 3D surface roughness (S_q, S_sk, and S_tr) and 3D surface dimension D_s. The results show that the main factors influencing surface roughness S_q is the spindle speed and followed by vibration amplitude, cutting depth, and feed rate. Surface fractal dimension D_s represents the ability of space filling of the machined surface and shows a weak-negative correlation with surface roughness S_q. Compared with S_q, D_s is more sensitive to the pit which is the main defect of machined surface. A large value of surface fractal dimension D_s corresponds to a better and exquisite surface finish. The main factors effecting the surface fractal dimension D_s are spindle speed and feed rate, and influencing degree of these two factors is similar. The influence order of process parameters on D_s is: feed rate > spindle speed > vibration amplitude > cutting depth.