An Energy Based Analytical Force Model for Orthogonal Cutting of Metal Matrix Composites

The machining of metal matrix composite (MMC) presents a significant challenge to the industry. The hard and abrasive nature of the reinforcement causes rapid tool wear and high machining cost. Cracking and debonding of the reinforcement particles are the significant damage modes that directly affect the tool performance. This paper presents, an energy based analytical force model that has been developed for orthogonal cutting processes. The total specific energy for deformation has been estimated along with the energy consumed for debonding as a function of volume fraction and material properties. Orthogonal cutting tests were carried out for a range of different feeds on different matrix materials and volume fractions. The results showed good agreement between the predicted and measured cutting forces.