Prediction of cutting forces in mill-grinding SiCp/Al composites

In this study, an analytical cutting force model has been presented for mill-grinding SiCp/Al composites. In this model, except the chip formation force and frictional force components, debonding and particle fracture force components are considered in modeling the total force. The energy theory of particle fracture and Griffith theory of fracture were applied in developing the debonding and particle fracture force components during mill-grinding SiCp/Al composites. Results of verification experiments for the developed cutting force model reveal that the mean forecast error of this developed cutting force model is less than 8% excluding few experimental values which deviate far from the corresponding theoretical model values, and has acceptable agreement with the experimental values under different machining conditions.