Currently, friction coefficient at a tool―chip―workpiece interface is simplified to a constant value. However, a friction coefficient that ignores the effects of temperature, pressure, and particle characteristics cannot characterize the frictional behaviours involved in cutting SiCp/Al composites. In this study, based on an inverse solution method, a novel customized device is developed to overcome the shortcoming of the determination of the workpiece surface temperature with a high local gradient. A series of "single-double" cutting inserts experiments are conducted on the device to measure the friction coefficient between the PCD tool―SiCp/Al composites. The friction coefficient model considering the temperature and particle property effects is established for the first time. The influence tendencies of the temperature, particle characteristics, and pressed depth on the friction coefficient are evaluated for varied SiCp/Al composites. The friction force model between the tool flank–workpiece is built considering the temperature gradient and particle characteristic effects. Finally, the analytical model of the cutting temperature subjected to orthogonal cutting SiCp/Al composite is developed by integrating the proposed friction coefficient and friction force models. The analytical results of the cutting temperature agree well with the experimental results, with a relative error smaller than 9.3 %. Compared with our previous study, the analytical model of the cutting temperature proposed in this study can improve the prediction accuracy significantly where the average relative error is reduced by 5%. This study offers a firm foundation for understanding frictional characteristics involved in cutting SiCp/Al composites.

目前，刀具-切屑-工件界面的摩擦系数被简化为一个常数值。然而，忽略温度、压力和颗粒特性影响的摩擦系数不能表征切割 SiCp/Al 复合材料所涉及的摩擦行为。在这项研究中，基于逆求解方法，开发了一种新颖的定制装置，以克服具有高局部梯度的工件表面温度确定的缺点。在该装置上进行了一系列“单双”切削刀片实验，以测量PCD刀具——SiCp/Al复合材料之间的摩擦系数。首次建立了考虑温度和颗粒特性影响的摩擦系数模型。温度的影响趋势，对于不同的 SiCp/Al 复合材料，评估了颗粒特性和压制深度对摩擦系数的影响。考虑温度梯度和颗粒特征效应，建立刀具后刀面-工件之间的摩擦力模型。最后，通过整合所提出的摩擦系数和摩擦力模型，开发了正交切削 SiCp/Al 复合材料的切削温度分析模型。切削温度分析结果与实验结果吻合较好，相对误差小于9.3%。与我们之前的研究相比，本研究提出的切削温度分析模型可以显着提高预测精度，平均相对误差降低5%。