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.
Skip Nav Destination
Article navigation
August 2018
Research-Article
Analytical Model of Cutting Force in Micromilling of Particle-Reinforced Metal Matrix Composites Considering Interface Failure
Ben Deng,
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
Research Center,
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: dengben@hust.edu.cn
Search for other works by this author on:
Lin Zhou,
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
Research Center,
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: zhoulin_1107@126.com
Search for other works by this author on:
Fangyu Peng,
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
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
Search for other works by this author on:
Rong Yan,
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
Research Center,
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: yanrong@hust.edu.cn
Search for other works by this author on:
Minghui Yang,
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
Research Center,
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: yang2472@foxmail.com
Search for other works by this author on:
Ming Liu
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
Research Center,
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: liuming426@hust.edu.cn
Search for other works by this author on:
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
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
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
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
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
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
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. Aug 2018, 140(8): 081009 (16 pages)
Published Online: June 4, 2018
Article history
Received:
November 4, 2017
Revised:
May 2, 2018
Citation
Deng, B., Zhou, L., Peng, F., Yan, R., Yang, M., and Liu, M. (June 4, 2018). "Analytical Model of Cutting Force in Micromilling of Particle-Reinforced Metal Matrix Composites Considering Interface Failure." ASME. J. Manuf. Sci. Eng. August 2018; 140(8): 081009. https://doi.org/10.1115/1.4040263
Download citation file:
Get Email Alerts
Design and Manufacture of Power Skiving Cutter From Target Circular Spline Geometry
J. Manuf. Sci. Eng (September 2023)
Experimental Investigation and Modeling of the Kerf Profile in Submerged Milling by Macro Abrasive Waterjet
J. Manuf. Sci. Eng (September 2023)
Modeling Variation in Multi-Station Compliant Assembly Using Parametric Space Envelope
J. Manuf. Sci. Eng (September 2023)
Thickness Control of Autoclave-Molded Composite Laminates
J. Manuf. Sci. Eng (September 2023)
Related Articles
Theoretical and Experimental Investigation on Inclined Ultrasonic Elliptical Vibration Cutting of Alumina Ceramics
J. Manuf. Sci. Eng (December,2016)
Tool Load Sensitivity Against Multidimensional Process Influences in Microblanking of Copper Foils With Silicon Punches
J. Manuf. Sci. Eng (September,2016)
High Rake Angle Orthogonal Machining of Highly Ordered Pyrolytic Graphite Parallel to the Basal Plane
J. Manuf. Sci. Eng (January,2016)
Calibration and Validation of a Mechanistic Micromilling Force Prediction Model
J. Manuf. Sci. Eng (January,2016)
Related Proceedings Papers
Related Chapters
Cutting Force Analysis of Turn-Milling Micro-Miniature Parts
International Conference on Mechanical Engineering and Technology (ICMET-London 2011)
Cutting Performance and Wear Mechanism of Cutting Tool in Milling of High Strength Steel 34CrNiMo6
Proceedings of the 2010 International Conference on Mechanical, Industrial, and Manufacturing Technologies (MIMT 2010)
Relationship Between Tool Deterioration and Cutting Force During Milling of a Nickel-Based Superalloy Using Cemented Carbide Tool
Advances in Multidisciplinary Engineering