Research Papers

Cutting Force Prediction on Micromilling Magnesium Metal Matrix Composites With Nanoreinforcements

[+] Author and Article Information
Chengying Xu

Department of Mechanical and
Aerospace Engineering
University of Central Florida,
Orlando, FL 32816

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF Micro AND Nano-Manufacturing. Manuscript received January 3, 2012; final manuscript received December 21, 2012; published online March 22, 2013. Assoc. Editor: J. Rhett Mayor.

J. Micro Nano-Manuf 1(1), 011010 (Mar 22, 2013) (10 pages) Paper No: JMNM-12-1002; doi: 10.1115/1.4023286 History: Received January 03, 2012; Revised December 21, 2012

Due to its light weight, high creep, and wear resistance, magnesium metal matrix composites (Mg-MMCs) with nanosized reinforcements are promising for various industrial applications, especially those with high volume fractions of reinforcements. The machinability of Mg-MMCs and related cutting process modeling are important to study. In this paper, an analytical cutting force model is developed to predict cutting forces of Mg-MMC reinforced with SiC nanoparticles in micromilling process. This model is different from previous ones by encompassing the behaviors of nanoparticle reinforcements in three cutting scenarios, i.e., shearing, ploughing, and elastic recovery. By using the enhanced yield strength in the cutting force model, three major strengthening factors are incorporated, including load-bearing effect, enhanced dislocation density strengthening effect, and Orowan strengthening effect. In this way, material properties, such as the particle size and volume fraction as significant factors affecting the cutting forces, are explicitly considered. To validate the model, experiments based on various cutting conditions using two types of end mills (diameters as 100 μm and 1 mm) were conducted on pure Mg, Mg-MMCs with volume fractions of 5 vol. %, 10 vol. %, and 15 vol. %. The experimental results show a good agreement with the predicted cutting force value.

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Fig. 1

Micromilling machine platform

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Fig. 2

Specific cutting energy versus nominal feed per tooth for pure Mg

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Fig. 3

Specific cutting energy versus nominal feed per tooth for 10 vol. % Mg-MMCs

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Fig. 4

Diagram of instantaneous chip thickness calculation

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Fig. 5

Simulated instantaneous chip load using two-flute end mill

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Fig. 6

Particle displacement in the elastic recovery zone

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Fig. 7

Particle displacement in the ploughing zone (a) deeper immersion and (b) shallower immersion

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Fig. 8

Particle displacement in the shearing zone

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Fig. 9

Dynamic response of the dynamometer along X direction from the impact hammer test

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Fig. 10

Specific cutting energy for 10 vol. % Mg-MMCs

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Fig. 11

Measured tool edge radius

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Fig. 12

Comparison of experimental and simulated cutting forces (on pure Mg)

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Fig. 13

Comparison of experimental and simulated cutting forces (on 10 vol. % Mg-MMCs)

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Fig. 14

Comparison of experimental and simulated cutting forces (on 10 vol. % Mg-MMCs)

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Fig. 15

Comparison of experimental and simulated cutting forces on 5 vol. % Mg-MMCs: (a)–(b), 10 vol. % Mg-MMCs: (c)–(d) and 15 vol. % Mg-MMCs: (e)–(f)



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