Metal matrix composites (MMCs) are commonly utilized materials in various industries, including applications in aerospace and automotive industries, due to their outstanding strength-to-weight ratio and wear resistance. The superior mechanical properties of MMCs are achieved through addition of hard ceramics as reinforcements to a metal matrix. However, these reinforcements also have a detrimental effect on the machinability of MMCs. The existence of ceramic reinforcements results in excessive tool wear. Moreover, the complications related to the mechanics of chip formation during MMC cutting further increase the complexity of the cutting process. Thus, in order to overcome the obstacles faced during machining, a comprehensive understanding of MMC cutting process is required.

In this thesis, a detailed understanding of MMC machining is accomplished through numerical and analytical modeling of the process. A finite element model of MMC cutting is developed for analysis of various unique aspects of the process, including the interactions between the cutting tool, the matrix, and the particles. The validity of the proposed model is confirmed by comparison between predicted and measured data. In the FE analysis, all major phases of MMC workpiece, namely the particle phase, the matrix phase, and the matrix-particle interface, are modeled. The developed finite element model provides insight into various scenarios of interactions between the cutting tool and particles as well as the effect of cutting process parameters on MMC behavior during machining.

Analytical models of MMC machining process are developed for prediction of cutting forces. These models rely on constitutive equations for capturing MMC behavior. Conventional constitutive equations, i.e. constitutive equations developed for modeling traditional monolithic materials, are lacking an explicit description of the effect of MMC’s unique features, namely particle size and volume fraction, on MMC behavior. Therefore, a novel constitutive equation is developed for depicting the MMC behavior during machining. This equation considers the fracture and debonding of MMC reinforcements during cutting and clarifies the relation between MMC behavior and particle size and volume fraction. Comparison of analytical model predictions with experimentally measured data verifies that the developed model is capable of providing an accurate depiction of MMC behavior during machining.