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<p>Ultra-high molecular weight polyethylene (UHMWPE) fiber composites are widely used in the defense equipment field due to its excellent wear resistance, low density and high impact energy absorption properties. Due to the low interlayer bonding strength of UHMWPE fiber composites, they are prone to generate burrs, delamination and other processing damages during the conventional hole-making process, which restricts their wide application. This paper conducted an experimental study on the ultrasonic vibration -assisted helical milling (UVHM) hole-making process of UHMWPE fiber composites, and analyzed the kinematic characteristics under UVHM. By comparing conventional helical milling (HM) and UVHM, the effects of process parameters on axial force, cutting temperature and surface quality of the hole wall were studied. The results demonstrate that UVHM significantly outperforms conventional processing: it reduces the axial force by an average of 9.88% (with a maximum reduction of 15.41%) and lowers the cutting temperature by up to 6.22%, due to the intermittent cutting action that decreases tool-workpiece engagement and heat accumulation. Furthermore, UVHM reduces surface roughness by an average of about 10%, promotes brittle fracture of fibers, and minimizes resin coating. These combined effects lead to a substantial improvement in hole-making quality for UHMWPE composites.</p>

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Research on ultrasonic vibration-assisted helical milling process and surface quality of UHMWPE fiber composites

  • 期刊论文

  • 发表日期：

    2026年2月15日

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  • Yaoting Wang,
  • Lei Zheng,
  • Zhiming Jiang,
  • Jinqi Zai,
  • Shuying Yang,
  • Zhengya Xu

摘要

Ultra-high molecular weight polyethylene (UHMWPE) fiber composites are widely used in the defense equipment field due to its excellent wear resistance, low density and high impact energy absorption properties. Due to the low interlayer bonding strength of UHMWPE fiber composites, they are prone to generate burrs, delamination and other processing damages during the conventional hole-making process, which restricts their wide application. This paper conducted an experimental study on the ultrasonic vibration -assisted helical milling (UVHM) hole-making process of UHMWPE fiber composites, and analyzed the kinematic characteristics under UVHM. By comparing conventional helical milling (HM) and UVHM, the effects of process parameters on axial force, cutting temperature and surface quality of the hole wall were studied. The results demonstrate that UVHM significantly outperforms conventional processing: it reduces the axial force by an average of 9.88% (with a maximum reduction of 15.41%) and lowers the cutting temperature by up to 6.22%, due to the intermittent cutting action that decreases tool-workpiece engagement and heat accumulation. Furthermore, UVHM reduces surface roughness by an average of about 10%, promotes brittle fracture of fibers, and minimizes resin coating. These combined effects lead to a substantial improvement in hole-making quality for UHMWPE composites.