Influence of cutting parameters on the depth of subsurface deformed layer in nano-cutting process of single crystal copper

Wang, Quanlong; Bai, Qingshun; Chen, Jiaxuan; Su, Hao; Wang, Zhiguo; Xie, Wenkun

doi:10.1186/s11671-015-1082-1

Cited by 38 publications

(15 citation statements)

References 22 publications

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“…Figure 7 indicates that there is a transition of material removal mechanisms from plowing to cutting with the increase of DOC. The observed DOC-dependent material removal mode is in agreement with previous studies [ 21 , 22 , 23 ].…”

Section: Resultssupporting

confidence: 92%

Atomistic and Experimental Investigation of the Effect of Depth of Cut on Diamond Cutting of Cerium

et al. 2018

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The ultra-precision diamond cutting process exhibits strong size effects due to the ultra-small depth of cut that is comparable with the cutting edge radius. In the present work, we elucidate the underlying machining mechanisms of single crystal cerium under diamond cutting by means of molecular dynamics simulations, with an emphasis on the evaluation of the effect of depth of cut on the cutting process by using different depths of cut. Diamond cutting experiments of cerium with different depths of cut are also conducted. In particular for the smallest depth of cut of 0.2 nm, shallow cutting simulations varying the sharpness of the cutting edge demonstrate that an atomically sharp cutting edge leads to a smaller machining force and better machined surface quality than a blunt one. Simulation results indicate that dislocation slip is the dominant deformation mechanism of cerium under diamond cutting with each depth of cut. Furthermore, the analysis of the defect zone based on atomic radial distribution functions demonstrates that there are trivial phase transformations from γ-Ce to δ-Ce occurred in both the machined surface and the formed chip. It is found that there is a transition of material removal mode from plowing to cutting with the increase of the depth of cut, which is also consistent with the diamond cutting experiments of cerium with different depths of cut.

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Section: Resultssupporting

confidence: 92%

Atomistic and Experimental Investigation of the Effect of Depth of Cut on Diamond Cutting of Cerium

et al. 2018

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“…4a and Fig. 4d To further quantitatively explore the generation of SSD layer in micro-machining of titanium alloy, the effect of cutting speed on dislocation morphologies was investigated in Fig 5. In comparison to previous MD studies, whose cutting speed stayed around 18000 m/min [37], the predictions matched well with actual operations. Results indicated that the subsurface microstructure exhibited hypersensitivity to increased cutting velocity.…”

Section: Resultssupporting

confidence: 76%

Theoretical model for subsurface microstructure prediction in micro-machining Ti-6Al-4V alloy – Experimental validation

Bai

Tong

et al. 2018

International Journal of Mechanical Sciences

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In this study, a new multiscale framework based on 2.5D discrete dislocation dynamics is proposed to predict the subsurface damaged layer evolution in micro-milling titanium alloy Ti-6Al-4V. This model takes into account the characteristics of component microstructure transformation and grain refinement by tracking the movement of matrix defects such as multiplication, slip, climb, cross-slip, junction and annihilation. Meanwhile, to understand the size dependence effect in micro-machining operation, a novel finite element orthogonal cutting model with dislocation density-based strain gradient constitutive equation is proposed and applied to reveal the farfield solution of driving stress of subsurface defect. The subsurface damaged layer characteristics including dislocation distribution and microstructure alteration of Ti-6Al-4V under various cutting conditions are studied with qualitative and quantitative assessment. The effects of processing parameters on subsurface features are analyzed. The obtained results have been compared with experimental findings utilizing the X-ray diffraction tests for validation purpose.

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“…However, most of these simulations usually adopt defect-free monocrystalline structures as the work material [3][4][5][6][7][8][9]. On the other hand, most engineering materials exist in polycrystalline forms and mechanical properties such as flow stress, yield stress and hardness of metals and alloys [10,11] dramatically scale with grain size.…”

Section: Introductionmentioning

confidence: 99%

Atomistic Insights on the Wear/Friction Behavior of Nanocrystalline Ferrite During Nanoscratching as Revealed by Molecular Dynamics

et al. 2017

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Using embedded atom method potential, extensive large-scale molecular dynamics (MD) simulations of nanoindentation/nanoscratching of nanocrystalline (nc) iron have been carried out to explore grain size dependence of wear response. MD results show no clear dependence of the frictional and normal forces on the grain size, and the single-crystal (sc) iron has higher frictional and normal force compared to nc-samples. For all samples, the dislocation-mediated mechanism is the primary cause of plastic deformation in both nanoindentation/nanoscratch. However, secondary cooperative mechanisms are varied significantly according to grain size. Pileup formation was observed in the front of and sideways of the tool, and they exhibit strong dependence on grain orientation rather than grain size. Tip size has significant impact on nanoscratch characteristics; both frictional and normal forces monotonically increase as tip radii increase, while the friction coefficient value drops by about 38%. Additionally, the increase in scratch depth leads to an increase in frictional and normal forces as well as friction coefficient. To elucidate the relevance of indentation/scratch results with mechanical properties, uniaxial tensile test was performed for nc-samples, and the result indicates the existence of both the regular and inverse Hall-Petch relations at critical grain size of 110.9 Å . The present results suggest that indentation/scratch hardness has no apparent correlation with the mechanical properties of the substrate, whereas the plastic deformation has.

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Influence of cutting parameters on the depth of subsurface deformed layer in nano-cutting process of single crystal copper

Cited by 38 publications

References 22 publications

Atomistic and Experimental Investigation of the Effect of Depth of Cut on Diamond Cutting of Cerium

Atomistic and Experimental Investigation of the Effect of Depth of Cut on Diamond Cutting of Cerium

Theoretical model for subsurface microstructure prediction in micro-machining Ti-6Al-4V alloy – Experimental validation

Atomistic Insights on the Wear/Friction Behavior of Nanocrystalline Ferrite During Nanoscratching as Revealed by Molecular Dynamics

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