An analytical power-based approach to predict orthogonal cutting force for sintered Al2124/SiC metal matrix composite

This paper presents a new analytical model for prediction of cutting forces in binary materials such as metal matrix composites (MMC) based on the cutting power. The model considers the effect of matrix shearing, reinforcement particles fracture and debonding as well as frictional contact between the tool and the particles to predict cutting forces required to form free surfaces. Linear orthogonal cutting on Al2124-SiC MMC with different cutting speed and depth of cuts were performed. The developed model shows a better performance compared with other available models in the literature to predict cutting forces while the experimental results reveal shearing and fracture as the main chip formation mechanism.