Nanometric cutting: Mechanisms, practices and future perspectives

Fang, Fengzhou; Lai, Min; Wang, Jinshi; Luo, Xichun; Yan, Jiwang; Yan, Yongda

doi:10.1016/j.ijmachtools.2022.103905

Cited by 54 publications

(13 citation statements)

References 263 publications

(422 reference statements)

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“…Currently, the machining conditions are usually selected empirically based on those of hard-brittle materials. Additionally, many auxiliary machining methods have been developed for machining hard-brittle materials, such as ion implantation-assisted machining and laser-assisted machining [183]. However, since the essential purpose of these methods is to reduce the hardness of the materials, they are not very effective for processing innately soft materials.…”

Section: Future Perspectivesmentioning

confidence: 99%

Effect of tool geometry on ultraprecision machining of soft-brittle materials: a comprehensive review

Huang

Yan

2023

Int. J. Extrem. Manuf.

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Brittle materials are widely used for producing important components in the industry of optics, optoelectronics, and semiconductors. Ultraprecision machining of brittle materials with high surface quality and surface integrity helps improve the functional performance and lifespan of the components. According to their hardness, brittle materials can be roughly divided into hard-brittle and soft-brittle ones. Although there have been some literature reviews for ultraprecision machining of hard-brittle materials, up to date, very few review papers are available that focus on the processing of soft-brittle materials. Due to the “soft” and “brittle” properties, this group of materials has unique machining characteristics. This paper presents a comprehensive overview of recent advances in ultraprecision machining of soft-brittle materials. Critical aspects of machining mechanisms such as chip formation, surface topography, and subsurface damage for different machining methods, including diamond turning, micro end milling, ultraprecision grinding, and micro/nano burnishing, are compared in terms of tool-workpiece interaction. The effects of tool geometries on the machining characteristics of soft-brittle materials are systematically analyzed, and dominating factors are sorted out. Problems and challenges in the engineering applications are pointed out, and solutions/guidelines for future R&D are provided.

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Section: Future Perspectivesmentioning

confidence: 99%

Effect of tool geometry on ultraprecision machining of soft-brittle materials: a comprehensive review

Huang

Yan

2023

Int. J. Extrem. Manuf.

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“…Clearly, time and length scale limitations inherent to MD simulation techniques imply that only nanometric cutting [ 25 , 26 ] experiments can be directly compared and combined with MD simulations, as recently carried out by Liu et al [ 27 ]. Nevertheless, simulation results are accurate in describing the local processes, and general conclusions can still be drawn.…”

Section: Introductionmentioning

confidence: 99%

Molecular Dynamics Simulation of Ti Metal Cutting Using a TiN:Ag Self-Lubricating Coated Tool

Lenzi

Marques

2023

Materials

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Silver-ceramic nanocomposite coatings, such as TiN:Ag, are among the most interesting solutions to improve the machining and cutting process of hard-to-cut Ti alloys, since they combine the TiN matrix hardness with the lubricating and protective action of Ag nanoparticles. Therefore, it is important to understand how, when present, Ag distributes at the tool-workpiece interface and how it affects the tribolayer formation and the tool wear. Molecular dynamics simulation results, obtained using a MEAM-based force field, are presented here for the cutting process of a Ti workpiece with a TiN tool, with and without the presence of Ag at the interface, for different cutting speeds. Ag is shown to form a thin protective layer at the workpiece-tool interface that prevents a direct contact between the parts and greatly reduces the tool degradation. Our simulations confirm the importance of Ag in self-lubricating nanocomposite coatings to realize the machining of otherwise hard-to-cut materials.

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“…high-accuracy optics, renewable energy instruments, and aerospace technology [1]. Polycrystalline materials are extensively employed in SPDT, and their surface roughness has a great impact on the service performance [2]. For instance, the scattering effect is usually observed if the surface roughness of a diamond-turned component is larger than a critical value, which further affects the optical performance [3].…”

Section: Introductionmentioning

confidence: 99%

A theoretical and deep learning hybrid model for predicting surface roughness of diamond-turned polycrystalline materials

He¹,

Yan²,

Wang³

et al. 2023

Int. J. Extrem. Manuf.

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Polycrystalline materials are extensively employed in industry. Its surface roughness has a great impact on the working performance. The material defect, particularly grain boundary, has great impact on the achieved surface roughness of polycrystalline materials. However, it is difficult to establish a purely theoretical model for surface roughness with consideration of the grain boundary effect using conventional analytical methods. In this work, a theoretical and deep learning hybrid model for predicting the surface roughness of diamond-turned polycrystalline materials is proposed. The kinematic-dynamic roughness component in relation to the tool profile duplication effect, work material plastic side flow, relative vibration between diamond tool and workpiece, etc. is theoretically calculated. The material-defect roughness component is modelled with a cascade forward neural network. In the neural network, the relative tool sharpness, work material properties (misorientation angle and grain size), and spindle rotation speed are configured as input variables. The material-defect roughness component is set as the output variable. To validate the developed model, polycrystalline copper with a gradient distribution of grains prepared by friction stir processing is machined with various processing parameters and different diamond tools. Compared with the previously developed model, obvious improvement on the prediction accuracy is observed with this hybrid prediction model. Based on this model, the influences of different factors on the surface roughness of polycrystalline materials are discussed. The influencing mechanism of the misorientation angle and grain size is quantitatively analysed. Two fracture mode, including transcrystalline and intercrystalline fracture at different relative tool sharpness is observed. Meanwhile, optimal processing parameters are obtained with a simulated annealing algorithm. Cutting experiments are performed with the optimal parameters, and a flat surface finish with Sa 1.314 nm is finally achieved.

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Nanometric cutting: Mechanisms, practices and future perspectives

Cited by 54 publications

References 263 publications

Effect of tool geometry on ultraprecision machining of soft-brittle materials: a comprehensive review

Effect of tool geometry on ultraprecision machining of soft-brittle materials: a comprehensive review

Molecular Dynamics Simulation of Ti Metal Cutting Using a TiN:Ag Self-Lubricating Coated Tool

A theoretical and deep learning hybrid model for predicting surface roughness of diamond-turned polycrystalline materials

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