Abstract
Finite element modeling for the machining of heterogeneous materials like particle-reinforced metal matrix composites has not been much successful as compared to homogeneous metals due to several issues. The most challenging issue is to deal with severe mesh distortion due to nonuniform deformation inside the workpiece. Other problems are related to the modeling of the interface between reinforcement particles and matrix and tool-reinforcement particle interaction. In this study, different strategies are adopted for finite element models (FEM) to cope with the above issues and comparative analyses have been performed. These 2D FE models are based on plane strain formulations and utilize a coupled temperature displacement method. The workpiece is modeled using reinforcement particle size and volume fraction inside the base matrix. The interface between the reinforcement particles and the matrix is modeled by using two approaches, with and without cohesive zone elements, and the chip separation is modeled with and without using a parting line. This allows models to simulate the local effects such as tool-reinforcement particle interaction and reinforcement particle debonding. In addition, the models can predict cutting forces, chip morphology, stresses, and temperature distributions. The effects of different methodologies on the model development, simulation runs, and predicted results have been discussed. The results are compared with experimental data, and it has been found that the utilization of cohesive zone elements (CZE) with the parting line approach seems to be the best one for the modeling of metal matrix composite (MMC) machining.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Chawla KK, Chawla N(2006) Metal‐matrix composites. Wiley Online Library
Shin Y, Dandekar C (2012) Mechanics and modeling of chip formation in machining of MMC. Machining of metal matrix composites, J. P. Davim, ed., Springer London, pp. 1–49
Zhu Y, Kishawy HA (2005) Influence of alumina particles on the mechanics of machining metal matrix composites. Int J Mach Tools Manuf 45(4):389–398
Looney LA, Monaghan JM, O’Reilly P, Taplin DMR (1992) The turning of an Al/SiC metal-matrix composite. J Mater Process Technol 33(4):453–468
Schwartz MM (1997) Composite materials. Volume 2: Processing, fabrication, and applications
Muthukrishnan N, Murugan M, Rao KP (2008) An investigation on the machinability of Al-SiC metal matrix composites using PCD inserts. Int J Adv Manuf Technol 38(5–6):447–454
Weinert K, König W (1993) A consideration of tool wear mechanism when machining metal matrix composites (MMC). CIRP Ann Manuf Technol 42(1):95–98
Quigley O, Monaghan J, O’Reilly P (1994) Factors affecting the machinability of an Al/SiC metal-matrix composite. J Mater Process Technol 43(1):21–36
Manna A, Bhattacharayya B (2003) A study on machinability of Al/SiC-MMC. J Mater Process Technol 140(1):711–716
Manna A, Bhattacharyya B (2004) Investigation for optimal parametric combination for achieving better surface finish during turning of Al/SiC-MMC. Int J Adv Manuf Technol 23(9–10):658–665
Manna A, Bhattacharayya B (2005) Influence of machining parameters on the machinability of particulate reinforced Al/SiC–MMC. Int J Adv Manuf Technol 25(9–10):850–856
El-Gallab M, Sklad M (1998) Machining of Al/SiC particulate metal-matrix composites: part I: tool performance. J Mater Process Technol 83(1):151–158
Camus G (2000) Modelling of the mechanical behavior and damage processes of fibrous ceramic matrix composites: application to a 2-D SiC/SiC. Int J Solids Struct 37(6):919–942
Arola D, Ramulu M (1997) Orthogonal cutting of fiber-reinforced composites: a finite element analysis. Int J Mech Sci 39(5):597–613
Nayak D, Bhatnagar N, Mahajan P (2005) Machining studies of UD-FRP composites part 2: finite element analysis. Mach Sci Technol 9(4):503–528
Venu Gopala Rao G, Mahajan P, Bhatnagar N (2007) Machining of UD-GFRP composites chip formation mechanism. Compos Sci Technol 67(11):2271–2281
Monaghan J, Brazil D (1998) Modelling the flow processes of a particle reinforced metal matrix composite during machining. Compos A: Appl Sci Manuf 29(1):87–99
Ramesh MV, Chan KC, Lee WB, Cheung CF (2001) Finite-element analysis of diamond turning of aluminium matrix composites. Compos Sci Technol 61(10):1449–1456
El-Gallab MS, Sklad MP (2004) Machining of aluminum/silicon carbide particulate metal matrix composites: part IV. Residual stresses in the machined workpiece. J Mater Process Technol 152(1):23–34
Pramanik A, Zhang LC, Arsecularatne JA (2007) An FEM investigation into the behavior of metal matrix composites: tool–particle interaction during orthogonal cutting. Int J Mach Tools Manuf 47(10):1497–1506
Zhou L, Huang ST, Wang D, Yu XL (2011) Finite element and experimental studies of the cutting process of SiCp/Al composites with PCD tools. Int J Adv Manuf Technol 52(5–8):619–626
Dandekar CR, Shin YC (2009) Multi-step 3-D finite element modeling of subsurface damage in machining particulate reinforced metal matrix composites. Compos A: Appl Sci Manuf 40(8):1231–1239
Dandekar CR, Shin YC (2010) Laser-assisted machining of a fiber reinforced metal matrix composite. J Manuf Sci Eng 132(6):061004
Iordanoff I, Richard D, Tcherniaieff S (2008) Discrete element method, a tool to investigate contacts in material forming. Int J Mater Form 1(1):1235–1238
Iliescu D, Gehin D, Iordanoff I, Girot F, Gutiérrez ME (2010) A discrete element method for the simulation of CFRP cutting. Compos Sci Technol 70(1):73–80
Chen Y, Kulasegaram S (2009) Numerical modelling of fracture of particulate composites using SPH method. Comput Mater Sci 47(1):60–70
Medina DF, Chen JK (2000) Three-dimensional simulations of impact induced damage in composite structures using the parallelized SPH method. Compos A: Appl Sci Manuf 31(8):853–860
Madaj M, Píška M (2013) On the SPH orthogonal cutting simulation of A2024-T351 alloy. Procedia CIRP 8:151–156
Pantalé O, Bacaria JL, Dalverny O, Rakotomalala R, Caperaa S (2004) 2D and 3D numerical models of metal cutting with damage effects. Comput Methods Appl Mech Eng 193(39–41):4383–4399
Dandekar CR (2010) Multi-scale modeling and laser-assisted machining of metal matrix composites. Ph.D thesis, Purdue University
Mass scaling, analysis techniques, ABAQUS analysis user manual, ABAQUS Documentation V 6.10. Dassault Systems
Fathipour M, Zoghipour P, Tarighi J, Yousefi R (2012) Investigation of reinforced sic particles percentage on machining force of metal matrix composite. Modern Applied Science, 6(8)
Particle elements, ABAQUS analysis user manual, ABAQUS Documentation, V 6.10. Dassault Systemes
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Umer, U., Ashfaq, M., Qudeiri, J.A. et al. Modeling machining of particle-reinforced aluminum-based metal matrix composites using cohesive zone elements. Int J Adv Manuf Technol 78, 1171–1179 (2015). https://doi.org/10.1007/s00170-014-6715-5
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-014-6715-5