Abstract
Metal Matrix Composites (MMCs) have demonstrated remarkable performance in many industrial applications due to their exceptional rigidity and resistance properties. However, they have not yet been utilized to their fullest because of impediments and challenges in their machining. Certainly, it highlights the significance and acquisition of relevant information concerning their machinability. Finite element (FE) simulation is one of the most universally acknowledged and sustainable tools for investigating the mechanism of machining. Therefore, this work presents two and three dimensional (2D and 3D) FE models to simulate the orthogonal cutting of silicon carbide (SiC) reinforced aluminum (Al)-based MMC. A 2D micromechanics based model (MM model) has been implemented to estimate the behavior of MMC machining based on particle size and volume fraction. In addition a 3D equivalent homogenous material model (EHM model) has also been developed based on a modified flow stress model which depends volume fraction of the MMC. The model outcomes in terms of cutting forces and temperature distributions have been discussed. It has been found that both models show comparable results with the experiments. The MM model is found to be efficient in predicting the local variables such as stress and temperature contours around the workpiece and cutting tool. However the global variables such as cutting forces and average tool-chip interface temperature can be predicted more easily with the EHM model as they are found to be computationally less expensive than the MM model.