Because of recent advances in precision engineering that allow controlled grinding infeed rates as small as several nanometers per grinding wheel revolution, it is possible to grind brittle materials so that the predominant material-removal mechanism is plastic-flow and not fracture. This process is known as ductile-regime grinding. When brittle materials are ground through a process of plastic deformation, surface finishes similar to those achieved in polishing or lapping are produced. Unlike polishing or lapping, however, grinding is a deterministic process, permitting finely controlled contour accuracy and complex shapes. In this paper, the development of a research apparatus capable of ductile-regime grinding is described. Furthermore, an analytical and experimental investigation of the infeed rates necessary for ductile-regime grinding of brittle materials is presented. Finally, a model is proposed, relating the grinding infeed rate necessary for ductile material-removal with the properties of the brittle workpiece material.

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We have synthesized artifact-free bulk nanocrystalline copper samples with a narrow grain size distribution (mean grain size of 23nm) that exhibited tensile yield strength about 11 times higher than that of conventional coarse-grained copper, while retaining a 14% uniform tensile elongation. In situ dynamic straining transmission electron microscope observations of the nanocrystalline copper are also reported, which showed individual dislocation motion and dislocation pile-ups. This suggests a dislocation-controlled deformation mechanism that allows for the high strain hardening observed. Trapped dislocations are observed in the individual nanograins.

Precision machining of germanium and silicon was studied using single-point diamond turning. Special attention was directed to the so-called ductile regime wherein optical quality surface finishes can be machined directly on brittle materials. A novel interrupted-cutting test and a new model of the machining process were used to measure a criticaldepth parameter experimentally. This parameter governs the transition from plastic flow to fracture along the tool nose. The critical-depth parameter can be used to provide physical insight into the effect of various machining parameters such as tool rake angle or tool clearance angle. Because of a complex interplay between tool geometry, machining parameters, and material response, a large fraction of material removal occurs by fracture even when ductileregime conditions are achieved. [