Influence of alumina particles on the mechanics of machining metal matrix composites

A plane-strain thermo-elasto-plastic finite element model has been developed and used to simulate orthogonal machining of alumina/aluminium 6061 metal matrix composite using a tungsten carbide tool. Simulations were carried out employing temperature-dependent material physical properties. The interface failure mode between the aluminium matrix and alumina particles was incorporated in this model. The model is used to investigate the effective and shear stresses on the alumina particles. Detailed results of the cutting forces generated during the machining process are presented and a comparison has been made with the experimental results for a range of feeds. Of particular interest are the contact stress distributions and alumina particle's interface failure. Normal and shear stresses and cutting temperatures were investigated. (C) 2004 Elsevier Ltd. All rights reserved.