Effect of tool wear progression on cutting forces and surface quality during cutting metal matrix composites

Abstract

Metal matrix composites (MMCs) have joined the group of difficult-to-cut materials because of the inherent abrasiveness of ceramic reinforcements. Flank wear is the dominant form of tool failure due to severe abrasion of the tool material by the reinforcements during cutting MMCs. The progression of tool wear is so rapid that sometimes the cutting tool lasts only for few seconds at high cutting speeds. The main objective of this paper is to investigate the changes in the magnitude of machining forces generated and the alterations in the quality of machined surface as a consequence of rapid tool wear progression during cutting aluminium MMCs. Dry cutting experiments were carried out on A356/SiC and 6061/Alumina aluminium MMCs. Different process parameters and cutting tool geometries were tested using coated and uncoated tungsten carbide inserts on MMCs reinforced with varying volume fractions and average particulate sizes. The experimental results showed a substantial increase in the cutting forces. The effect of wear progression on the obtained surface quality was also quantified. The results provide valuable information on the relationship between the generated machining forces, progression of tool wear and the resulted surface quality during machining MMCs.