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research-article

Analytical model of cutting force in micro milling of particle reinforced metal matrix composites considering interface failure

[+] Author and Article Information
Ben Deng

National NC System Engineering Research Center, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
dengben@hust.edu.cn

Lin Zhou

National NC System Engineering Research Center, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
zhoulin_1107@126.com

Fang Yu Peng

National NC System Engineering Research Center, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China; State Key Laboratory of Digital Manufacturing Equipment and Technology, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
zwm8917@263.net

Rong Yan

National NC System Engineering Research Center, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
yanrong@hust.edu.cn

Minghui Yang

National NC System Engineering Research Center, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
yang2472@foxmail.com

Ming Liu

National NC System Engineering Research Center, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
liuming426@hust.edu.cn

1Corresponding author.

ASME doi:10.1115/1.4040263 History: Received November 04, 2017; Revised May 02, 2018

Abstract

During the micro-machining processes of particle reinforced metal matrix composites, matrix-particle interface failure plays an important role in the cutting mechanism. This paper presents a novel analytical model to predict the cutting forces in micro milling of this material considering particle debonding caused by interface failure. The particle debonding is observed not only in the processed surface but also in the chip. A new algorithm is proposed to estimate the particles debonding force caused by interface failure with the aid of Nardin-Schultz model. Then, several aspects of the cutting force generation mechanism are considered in this paper, including: particles debonding force in the shear zone and build-up region, particles cracking force in the build-up region, shearing and ploughing forces of metal matrix, and varying sliding friction coefficient due to the reinforced particles in the chip-tool interface. The micro slot milling experiments are carried out on a self-made 3-axis high-precision machine tool, and the comparison between the predicted cutting forces and measured values shows that the proposed model can provide accurate prediction. Finally, the effects of interface failure, reinforced particles and tool edge radius on cutting forces are investigated by the proposed model and some conclusions are given as follows: the particles debonding force caused by interface failure is significant and takes averagely about 23% of the cutting forces under the given cutting conditions, reinforced particles and edge radius can greatly affect the micro milling process of particle reinforced metal matrix composites.

Copyright (c) 2018 by ASME
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