Modeling the effect of particle size while machining aluminum based metal matrix composite using an equivalent homogenous material approach

Due to their outstanding stiffness and resistant qualities, Metal Matrix Composites (MMCs) have exhibited extraordinary performance in a variety of industrial applications. However, due to constraints and challenges in their machining, they have not yet been fully employed. Indeed, it emphasizes the importance of obtaining essential information about their machinability. Finite element (FE) simulation is one of the most widely used and sustainable methods for studying machining mechanisms. In this study, 3D FE models based on equivalent homogenous material (EHM) approach are developed for MMCs to predict the effects of particle size on performance variables like cutting forces and maximum tool-chip interface temperatures. Turning experiments are conducted on MMC bars with 5, 10, and 15 µm' reinforcement particle sizes using the design of experiments based on the Sobol sequence. Cutting forces and other experimental data have been utilized to estimate equivalent Johnson cook parameters for the MMCs. The FE models' comparison with experiments shows good agreement for cutting force, thrust force, and maximum tool-chip interface temperatures.