Modeling machining of particle-reinforced aluminum-based metal matrix composites using cohesive zone elements

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.