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Research Papers

A Physics-Based Model for Metal Matrix Composites Deformation During Machining: A Modified Constitutive Equation

[+] Author and Article Information
M. N. A. Nasr

Department of Mechanical Engineering,
Faculty of Engineering,
Alexandria University,
Alexandria 21544, Egypt

A. Ghandehariun, H. A. Kishawy

Machining Research Laboratory (MRL),
Faculty of Engineering and Applied Science,
University of Ontario Institute
of Technology (UOIT),
Oshawa, ON L1H 7K4, Canada

1Corresponding author.

Contributed by the Materials Division of ASME for publication in the JOURNAL OF ENGINEERING MATERIALS AND TECHNOLOGY. Manuscript received April 29, 2016; final manuscript received August 1, 2016; published online October 6, 2016. Assoc. Editor: Marwan K. Khraisheh.

J. Eng. Mater. Technol 139(1), 011003 (Oct 06, 2016) (8 pages) Paper No: MATS-16-1128; doi: 10.1115/1.4034509 History: Received April 29, 2016; Revised August 01, 2016

One of the main challenges encountered in modeling the behavior of metal matrix composites (MMCs) during machining is the availability of a suitable constitutive equation. Currently, the Johnson–Cook (J–C) constitutive equation is being used, even though it was developed for homogeneous materials. In such a case, an equivalent set of homogeneous parameters is used, which is only suitable for a particular combination of particle size and volume fraction. The current work presents a modified form of the J–C constitutive equation that suits MMCs, and explicitly accounts for the effects of particle size and volume fraction, as controlled parameters. Also, an energy-based force model is presented, which considers particle cracking and debonding based on the principles of fracture mechanics. In order to validate the new approach, cutting forces were predicted and compared to experimental results, where a good agreement was found. In addition, the predicted forces were compared to other analytical models available in the literature.

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Figures

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Fig. 1

A schematic diagram of two-body abrasion parameters

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Fig. 2

Effect of feed rate on cutting force (Vf = 10%, d = 17 μm, v = 1 m/s, and γ = 6 deg)

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Fig. 3

Effect of cutting speed on cutting force (Vf = 20%, d = 25 μm, t1 = 0.1 mm, and γ = 0 deg)

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Fig. 4

Effect of particle size on cutting force (Vf = 10%, v = 0.5 m/s, t1 = 0.1 mm, and γ = 0 deg)

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Fig. 5

Effect of volume fraction on cutting force (d = 25 μm, v = 0.5 m/s, t1 = 0.1 mm, and γ = 0 deg)

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