Modeling of tool flank wear progression during orthogonal machining of metal matrix composites

This paper presents an analytical model for prediction of tool flank wear progression during orthogonal machining of aluminium based metal matrix composites (MMC's). The wear mechanisms and associated wear rates of the cutting tools used during machining MMC's are important issues to be understood in view of the high tool change down-time cost and machining cost involved. The objective of this study is to present a methodology to analytically model the tool flank wear progression as a function of tool and workpiece properties as well as cutting parameters during cutting metal matrix composites. The predicted tool wear rate is found to accelerate when the percentage and size of the ceramic reinforcement in the MMC exceeds a critical value. The proposed model was validated with orthogonal cutting tests conducted on 6061MMC reinforced with Al2O3 particulates of different mean sizes (9.5 mu m, 20 mu m, 25 mu m) and volume fractions (10% and 20%). Machining experiments were carried out for different cutting speeds (160m/min,222m/min, and 300m/min), constant feed (0.1mm) and width of cut (3mm). The results showed good agreement between the predicted and measured flank wear data.