Analytical model for force prediction when machining metal matrix composite

This paper presents an analytical force model to predict the forces generated during machining of metal matrix composites and investigates the effect of particle size on machining forces. Several aspects of the cutting mechanics such as shear force, ploughing force, and particle fracture force are considered to estimate the generated cutting forces. Chip formation force is obtained using the Johnson–Cook constitutive model. The ploughing force is formulated using the slip-line field theory, while the fracture force is calculated using Griffith Theory. The predicted results are compared to experimentally measured data under different conditions. The results show acceptable agreement between the theoretically predicted and experimentally measured cutting forces.

► Comprehensive analysis of all deformation mechanism encountered during cutting MMC.
► The analyses include the two and three body abrasion along the chip tool interface.
► Experimental verification of the presented work.