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A PARAMETRIC ANALYSIS OF CUTTING FORCES IN SINGLE-POINT DIAMOND TURNING OF Al6061/SiCp METAL MATRIX COMPOSITES (MMCs)

A detailed parametric analysis of cutting forces in diamond turning of Al6061/15SiCp composite is presented. Spectrum analysis was used to analyze the features of cutting force variation. It was found that the presence of SiC particles led to a large fluctuation in the cutting and thrust forces. The magnitude and frequency of the variation were found to be closely related to the cutting conditions. The use of higher feed rate, lower spindle speed, and smaller depth of cut significantly reduced both the magnitude and frequency of the cutting force variation. Compared with diamond turning of ductile materials, a much greater ratio of the thrust and cutting forces was obtained under various cutting conditions. Empirical cutting force equations are presented based on a nonlinear multiple regression analysis method. A good correlation between the actual and the predicted results was found. These findings can provide guidelines for the selection of optimal cutting conditions in minimizing the fluctuation of cutting forces.