Modeling of cutting force prediction in machining high-volume SiCp/Al composites

• Exact geometrical shape of tool is involved in the mathematical model. • Friction force comprises the sliding friction force and the rolling friction force. • Plough force is involved in the cutting force model due to the cutting edge radius . Variations in cutting forces significantly influence the tool wear and part quality in machining high-volume SiC-particle-reinforced aluminum matrix (SiCp/Al) composites. Properties of the reinforcement SiC particles, such as size and volume fraction, contribute to the change in the cutting forces. This paper presents a cutting force model based on the geometrical and mechanical nature of the tool and workpiece, considering the effect of the SiC reinforcement particles. The cutting force is predicted as three components ( F z , F x , and F y ) and the resultant cutting force F τ s . The cutting force was considered to generate three deformed zones: (a) shear deformed zone, (b) friction deformed zone on the chip–tool interface, (c) plow deformed zone. The effect of SiC reinforcement particles on friction deformed zone is analyzed emphatically. The friction force from friction deformed zone was obtained by calculating the sliding friction force and rolling friction force. To verify the feasibility and validity of the predicted model of cutting force, cutting experiments were performed with different combinations of cutting speed, feed rate, depth of cut, and tool nose radius. The predicted cutting force values demonstrate good agreement with the measured experimental cutting force values in most cutting conditions. The average percentages of the prediction error were 1.93%, 6.20%, and 10.48% for the F z , F x , and F y components, respectively, thus proving the validity and accuracy of the predicted model of cutting forces.