Modeling of force and temperature in cutting of particle reinforced metal matrix composites considering particle effects

Abstract

• An analytical force model for PRMMCs is established considering particle effects. • An analytical model of tool face temperature of PRMMCs is developed with particle effects. • Predictions considering particle effects accurately estimate experimental results. • Complex variations of force and temperature is strongly influenced by reinforced particles. Particle reinforced metal matrix composites (PRMMCs) machining is considerably difficult owing to the significant influence of hard particles on the force and temperature during cutting. To provide an insight for understanding the effect of particles on the force and temperature, this paper aimed at modeling of the force and temperature affected by reinforced particles in PRMMCs cutting. Firstly, an analytical force model of PRMMCs was established based on a dynamic constitutive model considering particle effects. The influences of hard particles on the shear strength in the shear zone were considered in the dynamic constitutive model, including particle strengthening effect and particle damage. The particle debonding and fracture near the cutting edge were additionally considered in the force model, based on an energy-based method. Then, an analytical model of tool face temperature with particle effects was developed by considering the characteristic of the heat generated in PRMMCs cutting. To predict force and temperature in PRMMCs cutting, a combined prediction method, which used an improved three-phase friction model, was proposed to integrate the force model with the temperature model. The predicted force and temperature in cutting of various PRMMCs under different cutting conditions were validated through a comparison with experimental results. The comparison results showed that the force and temperature predicted by the analytical models considering particle effects were found to be more accurate than the analytical models without considering particle effects. Finally, comprehensive investigation of the effect of reinforced particles on the cutting force and temperature was explored, based on the modeling of the force and temperature in PRMMCs cutting. The results indicated that the complex variation of forces with particle content and size mainly depended on the shear strength, which was strongly affected by particle damage. A decrease in tool face temperature with increasing particle content was caused by a reduction in the plastic shear energy of the metal matrix.