In the machining of mirror-like surfaces, a typical cutting depth of a few micrometers is common. With such a small depth of cut, chip formation takes place within individual grains of polycrystalline materials. In this article, orthogonal cutting of single copper crystals was performed in order to investigate the dependency of cutting deformation and surface quality on the crystallographic orientation of the substrate material. The experimental results show that the crystallographic orientation of the workpiece exerts a significant influence on the shear angle and the machined surface roughness. Cutting force variation with crystallographic orientation was analyzed on the basis of a microplasticity model. The trend in the variation of theoretical values of an effective Taylor factor (the shear strength) compares well with that of published experimental data on cutting forces.
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A modified smoothed particle hydrodynamics (SPH) method is applied to simulate the dynamic tensile failure of rock-like heterogeneous materials. The material heterogeneities are represented by different mechanical properties with a Weibull distribution at different particles over the specimen. An elasto-plastic-damage model is adopted to simulate material failure. Numerical simulations are performed for three specimens with different degrees of heterogeneity under quasi-static and dynamic loading conditions, respectively. The effects of strength criterion coefficient [Formula: see text] on the predicted tensile strength are also discussed. Results show that the material heterogeneity has significant effect on the dynamic tensile failure, especially at a higher strain rate loading condition. At a lower strain rate, the failure mode of heterogeneous material is very much similar to that of homogeneous materials. At a higher strain rate, plenty of micro cracks occur forming a failure band in the tension zones. Moreover, the value of strength criterion coefficient [Formula: see text] has a considerable influence on the tensile strength under a higher loading rate.
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