Modelling of tool flank−workpiece interface friction considering temperature gradient and particle property for cutting SiCp/Al composites

Currently, friction coefficient at a tool―chip―workpiece interface is simplified to a constant value. However, a friction coefficient that ignores the effects of temperature, pressure, and particle characteristics cannot characterize the frictional behaviours involved in cutting SiCp/Al composites. In this study, based on an inverse solution method, a novel customized device is developed to overcome the shortcoming of the determination of the workpiece surface temperature with a high local gradient. A series of "single-double" cutting inserts experiments are conducted on the device to measure the friction coefficient between the PCD tool―SiCp/Al composites. The friction coefficient model considering the temperature and particle property effects is established for the first time. The influence tendencies of the temperature, particle characteristics, and pressed depth on the friction coefficient are evaluated for varied SiCp/Al composites. The friction force model between the tool flank–workpiece is built considering the temperature gradient and particle characteristic effects. Finally, the analytical model of the cutting temperature subjected to orthogonal cutting SiCp/Al composite is developed by integrating the proposed friction coefficient and friction force models. The analytical results of the cutting temperature agree well with the experimental results, with a relative error smaller than 9.3 %. Compared with our previous study, the analytical model of the cutting temperature proposed in this study can improve the prediction accuracy significantly where the average relative error is reduced by 5%. This study offers a firm foundation for understanding frictional characteristics involved in cutting SiCp/Al composites.