Analyzing the machinability of metal matrix composites

Abstract

Abstract: The strength and the physical properties of composite materials are no doubt improved by the presence of the reinforcing particles. However, the higher energy requirement, the rapid tool wear and the associated poor surface finish during machining of metal matrix composites (MMCs) are leading drawbacks of the presence of the reinforcement particles. As a result, the applications of MMCs are still limited in certain areas. Understanding the deformation behavior and the effects of the reinforcement on the chip formation and the machinability is therefore crucial for proper tool selection, machining cost minimization and the expansion of MMCs to higher-volume applications. Several factors of the particulate, such as nature, shape, size, volume fraction and distribution, are responsible for the mechanical behavior of MMCs, and thereby the cutting forces and the tool wear mechanisms. Some of these process indicators are still difficult to predict not only because of the nature, size and distribution of the reinforcements but also due to role that these reinforcements play during chip formation and the way in which the particles are removed or cut. This chapter presents the effects of reinforcement on chip formation, tool wear and part quality during the machining of MMCs.