The experiment of PCD cutter and YG6X cutter milling SiCp/Al matrix composites was conducted, and the effect of tool material and machining parameters on cutting force and surface roughness was investigated, and the milling process of PCD tool was simulated with finite element software. The results showed that the axial thrust force was larger than the other two while precision milling 45% volume SiCp/Al matrix composites by YG6X tool, which resulting from great compressive strength of the material. The cutting force of PCD tool was much smaller than that of the YG6X, and the surface roughness of PCD tool was also smaller. Considering the cutting force and machining surface quality, YG6X should be used for rough machining, and PCD should be used for precision machining. The results of finite element simulation of PCD tools were in good agreement with experimental results, which can provide basis for production.
