In this paper, the simulation and experiment comparison of cutting force, cutting stress and chip morphology during the macro and nano cutting of single crystal copper are carried out. Firstly, a finite element method based on Johnson-Cook metal strength and failure model were used to establish a macro cutting model, and the cutting force, cutting stress, cutting displacement and chip morphology were obtained. Then a molecular dynamics simulation was used to establish a nano cutting model, and the cutting force, von mises stress and chip morphology were obtained. Afterwards, a comparative analysis of the two was carried out. Finally, the external turning experiment was used to verify the simulation results of the macro cutting model. The results show that: 1. The change trend of the cutting force in x and y directions are different,but the corresponding ratios of cutting forces in x and y directions in macro and nano cutting process are very close, and the corresponding ratios of the average macro and nano cutting forces in x and y directions are also very close. 2. The cutting stress in nano cutting process was about 100 times of macro cutting stress. 3. The chip length in macro cutting process is larger than the chip length in nano cutting process, and the shape is more regular. 4. The experimental cutting force change trend is very similar to the simulation cutting force change trend, but there exits difference in the value between the experiment cutting forces and simulated cutting forces.
In this paper,the FEM and MD method are used to establish macro and nano cutting model of OFHC copper,and the cutting force, cutting stress and subsurface deformation and phase change are compared and analyzed under the macro cutting depth (0.2mm, 0.3mm, 0.4mm) and nano cutting depth (0.8nm, 1.2nm, 1.6nm). Meanwhile, experiments are used to verify the simulated cutting force. The conclusions are below: The change trends of macro and nano cutting force are similar, and the ratios of the cutting forces in x and y directions at different cutting depths are similar. In addition, there are lateral chip both in the macro and nano cutting processes, showing a high degree of consistency. However, the nano cutting stress reached 25 times of that in the macro state.Then it was found that the area of unrecoverable plastic deformation on the surface increased with the increase of the cutting depth during the macro cutting process, but the existance depth of pure plastic deformation remained unchanged within 0.05mm.While in the nano cutting process, the proportion of FCC crystals converted to HCP crystals remains unchanged as the cutting depth increases,but the existance range is increasing. Finally, the amplitude and change trend of experimental and the simulated cutting force are highly consistent,which verifying the rationality of the macro simulated cutting model.
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