Analytical model of workpiece temperature in end milling in-situ TiB₂/7050Al metal matrix composites

At present, analytical models to predict cutting temperature of metal matrix composites do not exist. The objective of this study is to establish an analytical temperature model of workpiece machined by the bottom cutting edge during end milling in-situ TiB₂/7050Al metal matrix composites. In this model, the moving heat source method was applied with taking into consideration the tool flank wear effect, complex tool geometry of bottom cutting edge, dynamic heat flux and heat partition. Meanwhile, to meet the actual cutting facts, the effect of heating time was also considered. A dynamic cutting force model and the shear angle relationship were built for heat flux calculation and temperature modeling. With theoretical calculation and experimental data, the heat partition ratio, which stands for the heat conducted into workpiece, was found to increase linearly as thermal number increased. With validation, the proposed cutting temperature model was proved to be of good reliability and accuracy with the relative errors between prediction model and experiments being smaller than 18%. This analytical model will be of great significance for both the temperature modeling work of end milling process and analytical temperature modeling study of machining particle reinforced aluminum metal matrix composites.