Machining of Al/SiC particulate metal matrix composites part III: comprehensive tool wear models

A robust 3-D finite element model of a cutting tool is presented in this paper. The model takes into consideration the thermal and mechanical interactions at the tool/chip and tool/workpiece interfaces. Temperature-dependant material properties are incorporated in the model. The model was applied to the special case of the turning of Al/SiC particulate metal matrix composites, where high tool wear rates represent a challenge to the industry. The temperatures and stresses predicted by the model are in agreement with experimental measurements and tool wear observations. The wear patterns predicted by the model include crater wear, tool pitting and tool chipping. Thus, the model presented could be utilized in the selection of the tool material, geometry and cutting parameters that would result in the least tool wear, and hence helps to reduce machining costs and tool change down-time. Controlling tool wear is expected to enhance the surface integrity of the workpiece.