Study on the surface damage of green ZrO₂ ceramics in dry cutting based on discrete element method

Abstract

Discrete element simulation model and cutting tests are conducted to investigate the surface damage during the machining of green ZrO 2 ceramics.The discrete element simulation model (DEM) is developed based on the macroscopic physical and mechanical properties of the isostatically pressed green ZrO 2 ceramics. The validity of the simulation model is verified by cutting tests on green ZrO 2 ceramics. The results show that the physical and mechanical properties of the DEM model established by the PFC2D software are consistent with the macroscopic physical and mechanical properties of the green ZrO 2 ceramics. The depth of cut, the cutting speed, and the tool rake angles have a large effect on surface/subsurface cracks. The tool rear angle has large effect on the distribution of the peak residual stresses. When the cutting force increases suddenly, the number of cracks produced increases sharply. Smaller cutting force can reduce the number of cracks and surface damage.