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.

References

References
1.
Aust
,
E.
,
Elsaesser
,
M.
,
Hort
,
N.
, and
Limberg
,
W.
,
2006
, “
Machining of Hybrid Reinforced Mg-MMCs Using Abrasive Water Jetting
,”
7th Magnesium Technology Symposium
, pp.
345
348
.
2.
Goh
,
C. S.
,
Gupta
,
M.
,
Wei
,
J.
, and
Lee
,
L. C.
,
2007
, “
Characterization of High Performance Mg/MgO Nanocomposites
,”
J. Compos. Mater.
,
41
(
19
), pp.
2325
2335
.10.1177/0021998307075445
3.
Lim
,
C. Y. H.
,
Lim
,
S. C.
, and
Gupta
,
M.
,
2003
, “
Wear Behavior of SiCp-Reinforced Magnesium Matrix Composites
,”
Wear
,
255
, pp.
629
637
.10.1016/S0043-1648(03)00121-2
4.
Müller
,
F.
, and
Monaghan
,
J.
,
2000
, “
Non-Conventional Machining of Particle Reinforced Metal Matrix Composite
,”
Int. J. Mach. Tools Manuf.
,
40
(
9
), pp.
1351
1366
.10.1016/S0890-6955(99)00121-2
5.
Yao
,
Y.
,
2004
, “
Mill-Grinding Machining for Particle-Reinforced Aluminum Matrix Composites
,”
Progress of Machining Technology-Proceedings of the Seventh International Conference on Progress of Machining Technology
, Paper No. ICPMT'2004.
6.
Ferkel
,
H.
, and
Mordike
,
B. L.
,
2001
, “
Magnesium Strengthened by SiC Nanoparticles
,”
Mater. Sci. Eng. A
,
298
, pp.
193
199
.10.1016/S0921-5093(00)01283-1
7.
Cao
,
G.
,
Konishi
,
H.
, and
Li
,
X.
,
2008
, “
Mechanical Properties and Microstructure of Mg/SiC Nanocomposites Fabricated by Ultrasonic Cavitation Based Nanomanufacturing
,”
ASME Trans. J. Manuf. Sci. Eng.
,
130
, p.
031105
.10.1115/1.2823086
8.
He
,
F.
,
Han
,
Q.
, and
Jackson
,
M. J.
,
2008
, “
Nanoparticulate Reinforced Metal Matrix Nanocomposites
,”
Int. J. Nanopart.
,
1
(
4
), pp.
301
309
.10.1504/IJNP.2008.026473
9.
Poddar
,
P.
,
Mukherjee
,
S.
, and
Sahoo
,
K. L.
,
2009
, “
The Microstructure and Mechanical Properties of SiC Reinforced Magnesium Based Composites by Rheocasting Process
,”
J. Mater. Eng. Perform.
,
18
(
7
), pp.
849
855
.10.1007/s11665-008-9334-1
10.
Prabhu
,
B.
,
Suryanarayana
,
C.
, and
An
,
L.
,
2006
, “
Synthesis and Characterization of High Volume Fraction Al-Al2O3 Nanocomposite Powders by High-Energy Milling
,”
Mater. Sci. Eng. A
,
425
, pp.
192
200
.10.1016/j.msea.2006.03.066
11.
Jun
,
M.
,
Liu
,
X.
,
DeVor
,
R. E.
, and
Kapoor
,
S. G.
,
2006
, “
Investigation of the Dynamics of Microend Milling-Part I: Model Development
,”
ASME Trans. J. Manuf. Sci. Eng.
,
128
, pp.
893
900
.10.1115/1.2193546
12.
Malekian
,
M.
,
Park
,
S. S.
, and
Jun
,
M.
,
2009
, “
Modeling of Dynamic Micro-Milling Cutting Forces
,”
Int. J. Mach. Tools Manuf.
,
49
, pp.
586
598
.10.1016/j.ijmachtools.2009.02.006
13.
Vogler
,
M.
,
DeVor
,
R. E.
, and
Kapoor
,
S. G.
,
2003
, “
Microstructure-Level Force Prediction Model for Micro-Milling of Multi-Phase Materials
,”
ASME Trans. J. Manuf. Sci. Eng.
,
125
, pp.
202
209
.10.1115/1.1556402
14.
Vogler
,
M.
,
DeVor
,
R. E.
, and
Kapoor
,
S. G.
,
2004
, “
On the Modeling and Analysis of Machining Performance in Micro-Endmilling, Part II: Cutting Force Prediction
,”
ASME Trans. J. Manuf. Sci. Eng.
,
126
, pp.
695
705
.10.1115/1.1813471
15.
Newby
,
G.
,
Venkatachalam
,
S.
, and
Liang
,
S. Y.
,
2007
, “
Empirical Analysis of Cutting Force Constants in Micro-End-Milling Operations
,”
J. Mater. Process. Technol.
,
192–193
, pp.
41
47
.10.1016/j.jmatprotec.2007.04.026
16.
Liu
,
X.
,
DeVor
,
R. E.
, and
Kapoor
,
S. G.
,
2006
, “
An Analytical Model for the Prediction of Minimum Chip Thickness in Micromachining
,”
J. Manuf. Sci. Eng.
,
128
, pp.
474
481
.10.1115/1.2162905
17.
Lai
,
X.
,
Li
,
H.
,
Li
,
C.
,
Lin
,
Z.
, and
Ni
,
J.
,
2008
, “
Modelling and Analysis of Micro Scale Milling Considering Size Effect, Micro Cutter Edge Radius and Minimum Chip Thickness
,”
Int. J. Mach. Tools Manuf.
,
48
, pp.
1
14
.10.1016/j.ijmachtools.2007.08.011
18.
Li
,
C.
,
Lai
,
X.
,
Li
,
H.
, and
Ni
,
J.
,
2007
, “
Modeling of Three-Dimensional Cutting Forces in Micro-End-Milling
,”
J. Micromech. Microeng.
,
17
, pp.
671
678
.10.1088/0960-1317/17/4/001
19.
Pramanik
,
A.
,
Zhang
,
L. C.
, and
Arsecularatne
,
J. A.
,
2006
, “
Prediction of Cutting Forces in Machining of Metal Matrix Composites
,”
Int. J. Mach. Tools Manuf.
,
46
, pp.
1795
1803
.10.1016/j.ijmachtools.2005.11.012
20.
Zhang
,
Z.
, and
Chen
,
D. L.
,
2006
, “
Consideration of Orowan Strengthening Effect in Particulate-Reinforced Metal Matrix Nanocomposites: A Model for Predicting Their Yield Strength
,”
Scr. Mater.
,
54
, pp.
1321
1326
.10.1016/j.scriptamat.2005.12.017
21.
Chawla
,
N.
,
Deng
,
X.
, and
Schnell
,
D. R. M.
,
2006
, “
Thermal Expansion Anisotropy in Extruded SiC Particle Reinforced 2080 Aluminum Alloy Matrix Composites
,”
J. Mater. Sci. Eng. A
,
426
, pp.
314
322
.10.1016/j.msea.2006.04.054
22.
Li
,
J.
,
Liu
,
J.
, and
Xu
,
C.
,
2010
, “
Machinability Study of SiC Nanoparticles Reinforced Magnesium Nanocomposites During Micromilling Processes
,”
ASME Conference Proceedings of MSEC 2010
, Vol.
2
, pp.
391
398
.
23.
Liu
,
J.
,
Li
,
J.
,
Ji
,
Y.
, and
Xu
,
C.
,
2011
, “
Investigation on the Effect of SiC Nanoparticles on Cutting Forces for Micro-Milling Magnesium Matrix Composites
,”
ASME Conference Proceedings of MSEC 2011
, Vol.
2
, pp.
525
536
.
You do not currently have access to this content.