Dynamic cutting force model for cutting SiCp/Al composites considering particle characteristics stochastic models

Abstract Because the particle shape, size, and spacing in SiCp/Al composites are not constant, the stochastic fluctuation phenomenon of their cutting force is more remarkable than those of continuous materials. This study aims to develop an analytical model of the dynamic cutting force in the orthogonal cutting of SiCp/Al composites. The stochastic models of the particle volume fraction, particle size, and aspect ratio are established. Based on analysing the mechanical mechanisms in different zones and the heat generation mechanisms in the shear and rubbing sources in the cutting process, a dynamic cutting force model is developed for SiCp/Al composites. This model considers the stochasticity of the particle characteristics and the dynamic change characteristic of heat generation. The predicted results yielded the average and maximum relative errors for the tangential force as 7.29% and 9.86%, respectively, and those for the radial force as 7.36% and 10.33%, respectively. Comparison of the analytical and experimental results presents a good agreement. The effects of the cutting parameters and the tool wear on the average cutting force in the orthogonal cutting of SiCp/Al composites are discussed. Moreover, the effects of the particle characteristics on each component of the cutting force are also analysed. In particular, the dynamic cutting force model can accurately present the dynamic fluctuation characteristics of the cutting process of SiCp/Al composites and study the variation tendency of average cutting force. This work provokes more in-depth thoughts of dynamic fluctuation details in the cutting process and provides the guiding significance for industrial SiCp/Al composites machining.