0
Research Papers

Analytical Model of Cutting Force in Micromilling 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
e-mail: 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
e-mail: zhoulin_1107@126.com

Fangyu 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
e-mail: 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
e-mail: 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
e-mail: 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
e-mail: liuming426@hust.edu.cn

1Corresponding author.

Manuscript received November 4, 2017; final manuscript received May 2, 2018; published online June 4, 2018. Assoc. Editor: Guillaume Fromentin.

J. Manuf. Sci. Eng 140(8), 081009 (Jun 04, 2018) (16 pages) Paper No: MANU-17-1685; doi: 10.1115/1.4040263 History: Received November 04, 2017; Revised May 02, 2018

During the micromachining processes of particle-reinforced metal matrix composites (PMMCs), 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 micromilling 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 coefficients due to the reinforced particles in the chip-tool interface. The micro-slot milling experiments are carried out on a self-made three-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 micromilling process of PMMCs.

Copyright © 2018 by ASME
Your Session has timed out. Please sign back in to continue.

References

Kaczmar, J. W. , Pietrzak, K. , and Włosiński, W. , 2000, “ The Production and Application of Metal Matrix Composite Materials,” J. Mater. Process. Technol., 106(1–3), pp. 58–67. [CrossRef]
Kyritsis, D. C. , Roychoudhury, S. , McEnally, C. S. , Pfefferle, L. D. , and Gomez, A. , 2004, “ Mesoscale Combustion: A First Step Towards Liquid Fueled Batteries,” Exp. Therm. Fluid Sci, 28(7), pp. 763–770. [CrossRef]
Deng, W. , 2008, “ Fundamentals and Applications of Multiplexed Electrosprays,” Ph.D. dissertation, Yale University, New Haven, CT.
Pramanik, A. , 2014, “ Developments in the Non-Traditional Machining of Particle Reinforced Metal Matrix Composites,” Int. J. Mach. Tools Manuf., 86(11), pp. 44–61. [CrossRef]
Liu, J. , Li, J. , and Xu, C. Y. , 2014, “ Interaction of the Cutting Tools and the Ceramic-Reinforced Metal Matrix Composites During Micro-Machining: A Review,” CIRP J. Manuf. Sci. Technol., 7(2), pp. 55–70. [CrossRef]
Waldorf, D. J. , DeVor, R. E. , and Kapoor, S. G. , 1998, “ A Slip-Line Field for Ploughing During Orthogonal Cutting,” ASME J. Manuf. Sci. Eng., 120(4), pp. 693–699. [CrossRef]
Vogler, M. P. , Kapoor, S. G. , and DeVor, R. E. , 2004, “ On the Modeling and Analysis of Machining Performance in Micro-End Milling—Part II: Cutting Force Prediction,” ASME J. Manuf. Sci. Eng., 126(4), pp. 695–705. [CrossRef]
Fang, N. , 2003, “ Slip-Line Modelling of Machining With a Rounded-Edge Tool—Part I: New Model and Theory,” J. Mech. Phys. Solids, 51(4), pp. 715–742. [CrossRef]
Jin, X. , and Altintas, Y. , 2011, “ Slip-Line Field Model of Micro-Cutting Process With round Tool Edge Effect,” J. Mater. Process. Technol., 211(3), pp. 339–355. [CrossRef]
Davim, J. P. , 2002, “ Diamond Tool Performance in Machining Metal-Matrix Composites,” J. Mater. Process. Technol., 128(1–3), pp. 100–105. [CrossRef]
Dandekar, C. R. , and Shin, Y. C. , 2012, “ Modeling of Machining of Composite Materials: A Review,” Int. J. Mach. Tools Manuf., 57(2), pp. 102–121. [CrossRef]
Kishawy, H. A. , Kannan, S. , and Balazinski, M. , 2004, “ An Energy Based Analytical Force Model for Orthogonal Cutting of Metal Matrix Composites,” CIRP Ann.—Manuf. Technol., 53(1), pp. 91–94. [CrossRef]
Pramanik, A. , Zhang, L. C. , and Arsecularatne, J. A. , 2006, “ Prediction of Cutting Forces in Machining of Metal Matrix Composites,” Int. J. Mach. Tools Manuf., 46(14), pp. 1795–1803. [CrossRef]
Dabade, U. A. , Dapkekar, D. , and Joshi, S. S. , 2009, “ Modeling of Chip-Tool Interface Friction to Predict Cutting Forces in Machining of Al/SiCp Composites,” Int. J. Mach. Tools Manuf., 49(9), pp. 690–700. [CrossRef]
Sikder, S. , and Kishawy, H. A. , 2012, “ Analytical Model for Force Prediction When Machining Metal Matrix Composite,” Int. J. Mech. Sci., 59(1), pp. 95–103. [CrossRef]
Ghandehariun, A. , Hussein, H. M. , and Kishawy, H. A. , 2016, “ Machining Metal Matrix Composites: Novel Analytical Force Model,” Int. J. Adv. Manuf. Technol., 83(1-4), pp. 233–241. [CrossRef]
Ghandehariun, A. , Kishawy, H. A. , and Balazinski, M. , 2016, “ On Machining Modeling of Metal Matrix Composites: A Novel Comprehensive Constitutive Equation,” Int. J. Mech. Sci., 107, pp. 235–241. [CrossRef]
Nasr, M. N. A. , Ghandehariun, A. , and Kishawy, H. A. , 2017, “ A Physics-Based Model for Metal Matrix Composites Deformation During Machining: A Modified Constitutive Equation,” ASME J. Eng. Mater. Technol., 139(1), p. 011003. [CrossRef]
Jiang, L. Y. , Nath, C. , Samuel, J. , and Kapoor, S. G. , 2014, “ Estimating the Cohesive Zone Model Parameters of Carbon Nanotube-Polymer Interface for Machining Simulations,” ASME J. Manuf. Sci. Eng., 136(3), p. 031004. [CrossRef]
Jarząbek, D. M. , Chmielewski, M. , and Wojciechowski, T. , 2015, “ The Measurement of the Adhesion Force Between Ceramic Particles and Metal Matrix in Ceramic Reinforced-Metal Matrix Composites,” Compos. Part A: Appl. Sic. Manuf., 76, pp. 124–130. [CrossRef]
Pramanik, A. , Zhang, L. C. , and Arsecularatne, J. A. , 2007, “ An FEM Investigation Into the Behavior of Metal Matrix Composites: Tool-Particle Interaction During Orthogonal Cutting,” Int. J. Mach. Tools Manuf., 47(10), pp. 1497–1506. [CrossRef]
Liu, J. , Li, J. , and Xu, C. Y. , 2013, “ Cutting Force Prediction on Micromilling Magnesium Metal Matrix Composites With Nanoreinforcements,” ASME J. Micro Nano-Manuf., 1(1), p. 011010. [CrossRef]
Nardin, M. , and Schultz, J. , 1996, “ Relationship Between Work of Adhesion and Equilibrium Interatomic Distance at the Interface,” Langmuir, 12(17), pp. 4238–4242. [CrossRef]
Zhou, L. , Peng, F. Y. , Yan, R. , Yao, P. F. , Yang, C. C. , and Li, B. , 2015, “ Analytical Modeling and Experimental Validation of Micro End-Milling Cutting Forces Considering Edge Radius and Material Strengthening Effects,” Int. J. Mach. Tools Manuf., 97, pp. 29–41. [CrossRef]
Quan, Y. M. , Zhou, Z. H. , and Ye, B. Y. , 1999, “ Cutting Process and Chip Appearance of Aluminum Matrix Composites Reinforced by SiC Particle,” J. Mater. Process. Technol., 91(1–3), pp. 231–235. [CrossRef]
Lin, J. T. , Bhattacharyya, D. , and Ferguson, W. G. , 1998, “ Chip Formation in the Machining of SiC-Particle-Reinforced Aluminium-Matrix Composites,” Compos. Sci. Technol., 58(2), pp. 285–291. [CrossRef]
Davis, B. , Dabrow, D. , Ju, L. C. , Li, A. H. , Xu, C. Y. , and Huang, Y. , 2017, “ Study of Chip Morphology and Chip Formation Mechanism During Machining of Magnesium-Based Metal Matrix Composites,” ASME J. Manuf. Sci. Eng., 139(9), p. 091008. [CrossRef]
Sun, L. Z. , Liu, H. T. , and Ju, J. W. W. , 2015, “ Particle-Cracking Modeling of Metal Matrix Composites,” Handbook of Damage Mechanics, Springer, New York, pp. 1147–1162.
Jiang, Y. P. , 2016, “ An Analytical Model for Particulate Reinforced Composites (PRCs) Taking Account of Particle Debonding and Matrix Cracking,” Mater. Res. Express, 3(10), p. 106501. [CrossRef]
Lee, H. K. , 2001, “ A Computational Approach to the Investigation of Impact Damage Evolution in Discontinuously Reinforced Fiber Composites,” Comp. Mech., 27(6), pp. 504–512. [CrossRef]
Johnson, G. R. , and Cook, W. H. , 1983, “ A Constitutive Model and Data for Metals Subjected to Large Strains, High Strain Rates and High Temperatures,” Seventh International Symposium on Ballistics, Hague, The Netherlands, Apr. 19–21, pp. 541–547.
Manjunathaiah, J. , and Endres, W. J. , 2000, “ A New Model and Analysis of Orthogonal Machining With an Edge-Radiused Tool,” ASME J. Manuf. Sci. Eng., 122(3), pp. 384–390. [CrossRef]
Basuray, P. K. , Misra, B. K. , and Lal, G. K. , 1977, “ Transition From Ploughing to Cutting During Machining With Blunt Tools,” Wear, 43(3), pp. 341–349. [CrossRef]
Manjunathaiah, J. , 1998, “ Analysis and a New Model for the Orthogonal Machining Process in the Presence of Edge-Radiused (Non-Sharped) Tools,” Ph.D. dissertation, University of Michigan, Ann Arbor, MI. https://deepblue.lib.umich.edu/handle/2027.42/131272
Ozlu, E. , Budak, E. , and Molinari, A. , 2009, “ Analytical and Experimental Investigation of Rake Contact and Friction Behavior in Metal Cutting,” Int. J. Mach. Tools Manuf., 49(11), pp. 865–875. [CrossRef]
Pramanik, A. , Zhang, L. C. , and Arsecularatne, J. A. , 2008, “ Machining of Metal Matrix Composites: Effect of Ceramic Particles on Residual Stress, Surface Roughness and Chip Formation,” Int. J. Mach. Tools Manuf., 48(15), pp. 1613–1625. [CrossRef]
Liu, H. T. , 2010, “ Research on Residual Stresses and Deformation of Thin-Walled Precision Rotary Parts Induced by Machining,” Ph.D. dissertation, Harbin Institute of Technology, Harbin, China.
Bian, R. , He, N. , Li, L. , Zhan, Z. B. , Wu, Q. , and Shi, Z. Y. , 2014, “ Precision Milling of High Volume Fraction SiCp/Al Composites With Monocrystalline Diamond End Mill,” Int. J. Adv. Manuf. Technol., 71(1–4), pp. 411–419. [CrossRef]
Fang, N. , 2005, “ A New Quantitative Sensitivity Analysis of the Flow Stress of 18 Engineering Materials in Machining,” ASME J. Eng. Mater. Technol., 127(2), pp. 192–196. [CrossRef]
Zhang, W. , Wei, G. , and Xiao, X. K. , 2013, “ Constitutive Relation and Fracture Criterion of 2A12 Aluminum Alloy,” Acta Armamentarii, 34(3), pp. 276–282.
Monaghan, J. , and Brazil, D. , 1998, “ Modelling the Flow Processes of a Particle Reinforced Metal Matrix Composite During Machining,” Compos. Part A: Appl. Sci. Manuf., 29(1–2), pp. 87–99. [CrossRef]
Venkatachalam, S. , Fergani, O. , Li, X. P. , Yang, J. G. , Chiang, K. N. , and Liang, S. Y. , 2015, “ Microstructure Effects on Cutting Forces and Flow Stress in Ultra-Precision Machining of Polycrystalline Brittle Materials,” ASME J. Manuf. Sci. Eng., 137(2), p. 021020. [CrossRef]

Figures

Grahic Jump Location
Fig. 1

Transmission electron microscope (TEM) images of PMMCs that are shaped by different methods: (a) 40 vol % SiCp/Al shaped by powder metallurgy, (b) 45 vol % SiCp/2a12 shaped by pressure infiltration, and (c) FEI Tecnai G2 F30

Grahic Jump Location
Fig. 2

PMMCs micromilling process for two-flute ball-end mill

Grahic Jump Location
Fig. 3

SEM images of SiCp/Al processed surface in micromilling: (a) particle cracking in the SiCp/Al surface, (b) particle debonding in the SiCp/Al surface, and (c) FEI Helios NanoLab G3 CX

Grahic Jump Location
Fig. 4

PMMCs cutting forces model based on the slip-line field model proposed by Waldorf et al. [6]

Grahic Jump Location
Fig. 5

Particles debonding process under the rounded tool edge in the microcutting of PMMCs

Grahic Jump Location
Fig. 6

SEM images of the chip in the micromilling of PMMCs

Grahic Jump Location
Fig. 7

The process of particle debonding that is caused by interface failure in the shear zone

Grahic Jump Location
Fig. 8

Flow chart of cutting force analytical model in micromilling of PMMCs

Grahic Jump Location
Fig. 9

PMMCs micro ball-end milling setup on three-axis high-precision machine tool

Grahic Jump Location
Fig. 10

Tool edge radius measurement of micro ball-end mill in Laser scanning confocal microscope

Grahic Jump Location
Fig. 11

Comparisons between predicted cutting forces and measured cutting forces in micromilling of 40 vol %SiCp/Al: (a) condition 1, (b) condition 2, and (c) condition 3

Grahic Jump Location
Fig. 12

Comparisons between predicted cutting forces and measured cutting forces in micro milling of 45 vol %SiCp/Al2a12: (a) condition 4, (b) condition 5, and (c) condition 6

Grahic Jump Location
Fig. 13

The effect of interface failure on cutting forces: (a) The effect of interface thickness, (b) the effect of adhesion work, (c) the contribution of different parts to cutting force amplitude in the X-direction, and (d) the contribution of different parts to cutting force amplitude in the Y-direction

Grahic Jump Location
Fig. 14

The effect of particle volume fraction on cutting forces: (a) cutting force amplitude in the X-direction and (b) cutting force amplitude in the Y-direction

Grahic Jump Location
Fig. 15

The effect of particle size on micro cutting processes of PMMCs: (a) the effect of particle size on cutting forces, (b) the SEM image of the processed surface of 45 vol % SiCp/2a12, and (c) the SEM image of the processed surface of 40 vol % SiCp/Al

Grahic Jump Location
Fig. 16

The effect of cutting edge radius on cutting forces: (a) cutting force amplitude in the X-direction and (b) cutting force amplitude in the Y-direction

Tables

Errata

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In