Analytical model for force prediction when machining metal matrix composites
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Metal Matrix Composites (MMC) offer several thermo-mechanical advantages over standard materials and alloys which make them better candidates in different applications. Their light weight, high stiffness, and strength have attracted several industries such as automotive, aerospace, and defence for their wide range of products. However, the wide spread application of Meal Matrix Composites is still a challenge for industry. The hard and abrasive nature of the reinforcement particles is responsible for rapid tool wear and high machining costs. Fracture and debonding of the abrasive reinforcement particles are the considerable damage modes that directly influence the tool performance. It is very important to find highly effective way to machine MMCs. So, it is important to predict forces when machining Metal Matrix Composites because this will help to choose perfect tools for machining and ultimately save both money and time. This research presents an analytical force model for predicting the forces generated during machining of Metal Matrix Composites. In estimating the generated forces, several aspects of cutting mechanics were considered including: shearing force, ploughing force, and particle fracture force. Chip formation force was obtained by classical orthogonal metal cutting mechanics and the Johnson-Cook Equation. The ploughing force was formulated while the fracture force was calculated from the slip line field theory and the Griffith theory of failure. The predicted results were compared with previously measured data. The results showed very good agreement between the theoretically predicted and experimentally measured cutting forces.