Characterization of the material-induced elastic–plastic deformations in ultra-precision diamond cutting

Wang, Sujuan; Sun, Hao; Ma, Huijuan; Feng, Xin; Yin, Ziqiang

doi:10.1007/s40430-019-1872-y

Cited by 4 publications

(2 citation statements)

References 44 publications

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“…While internal microstructures of workpiece materials have feature sizes that are comparable with both the cutting edge radius of SCD tool and the depth of cut (DOC), the microstructure-dominated properties of specimen have a large influence on the diamond cutting process. Furthermore, the size effect associated with the ultra-small material removal thickness magnifies the impact of elastic-plastic deformation of workpiece materials in diamond cutting process [15,16]. Thus, workpiece material and diamond tool are highly coupled in the diamond cutting process, for which revealing the dependence of machining response on the properties of workpiece material is essentially needed.…”

Section: Introductionmentioning

confidence: 99%

Numerical simulation of materials-oriented ultra-precision diamond cutting: review and outlook

Zhao

Zhang

et al. 2023

Int. J. Extrem. Manuf.

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Ultra-precision diamond cutting is a promising machining technique for realizing ultra-smooth surface of different kinds of materials. While fundamental understanding of the impact of workpiece material properties on cutting mechanisms is crucial for promoting the capability of the machining technique, numerical simulation methods at different length and time scales act as important supplements to experimental investigations. In this work, we present a compact review on recent advancements in the numerical simulations of material-oriented diamond cutting, in which representative machining phenomena are systematically summarized and discussed by multiscale simulations such as molecular dynamics simulation and finite element simulation: the anisotropy cutting behavior of polycrystalline material, the thermos-mechanical coupling tool-chip friction states, the synergetic cutting responses of individual phase in composite materials, and the impact of various external energetic fields on cutting processes. In particular, the novel physics-based numerical models, which involve the high precision constitutive law associated with heterogeneous deformation behavior, the thermo-mechanical coupling algorithm associated with tool-chip friction, the configurations of individual phases in line with real microstructural characteristics of composite materials, and the integration of external energetic fields into cutting models, are highlighted. Finally, insights into the future development of advanced numerical simulation techniques for diamond cutting of advanced structured materials are also provided. The aspects reported in this review present guidelines for the numerical simulations of ultra-precision mechanical machining responses for a variety of materials.

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Section: Introductionmentioning

confidence: 99%

Numerical simulation of materials-oriented ultra-precision diamond cutting: review and outlook

Zhao

Zhang

et al. 2023

Int. J. Extrem. Manuf.

View full text Add to dashboard Cite

show abstract

“…7 Currently, UPDM can be employed into difficult-to-cut materials such as hard and brittle materials and it also offers the highest flexibility for the fabrication of freeform surfaces and micro-structured surfaces. 8,9 Although UPDM exhibits such capabilities, it is sensitive the cutting parameters, 10 material effects, 10 tool geometry, 11 chip formation, 11 and spindle vibration, 12 etc. Surface generation has always been a hot topic in manufacturing process.…”

Section: Introductionmentioning

confidence: 99%

A theoretical and experimental investigation into surface generation in ultra-precision diamond milling

Guo

Gao

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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Ultra-precision diamond milling (UPDM) provides a promising generation of high-quality surface up to sub-micrometric form accuracy and nanometric surface roughness. Prior to its machining process, the investigation on surface generation would be beneficial to achieve desired quality with reduced cost and boosted productivity. However, few studies discussed this issue so far. In this study, a theoretical and experimental investigation into surface generation was carried out in UPDM. Firstly, a geometric model was built up considering the material removal process between the milling tool and the workpiece. Secondly, surface generation process was elaborated according to the developed model. Finally, UPDM experiments were performed on a typical brass material at different cutting conditions and surface texture parameters were characterized according to ISO 25178-2. Autocorrelation function (ACF) analysis was employed for a detailed evaluation of surface generation. The results showed that the static factors (cutting parameters) as well as the dynamic factors (material effects and spindle vibration), which were associated with the cutting conditions, yielded a great influence on surface generation. Surface texture characterization indicated that there was a good consistence between simulation and experiment, demonstrating the feasibility of the proposed method. ACF analysis indicated that, with the increased feedrate/step ratio, surface generation approximately achieved a transition from the periodical surface (dominated by cutting residuals) to the random surface (determined by multiple components). Significantly, this study draws up a fundamental understanding toward surface generation in UPDM.

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Advancement of Analytical Model for Hydrophobic Rectangular Pillared Array on Al-Surface and Its Experimental Validation

Jaishree,

Bhandari,

Khatri

et al. 2024

Int. J. Precis. Eng. Manuf.

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Over the past few decades, self-cleaning surfaces have been significantly investigated due to their commercial applications in various fields. However, the researchers are still lagging in developing better mathematical models and fabricating hydrophobic surfaces for direct espousal in industry. In this study, a force-balanced system-based mathematical model is modified for a rectangular pillared array-based micro-structure and MATLAB simulations were used to validate it theoretically. The same pattern was developed on Al-surface using a single-point diamond turning (SPDT) machine experimentally. The experimental results were validated using coherence correlation interferometry (CCI), optical microscopy, drop shape analyser (DSA), and field emission scanning electron microscopy (FESEM). The experimentally estimated and theoretically predicted contact angles of the rectangular pillared array are found in close agreement. Further, the advancement in mathematical models and models-based surface manufacturing strategies can boost the research in this domain to develop robust self-cleaning hydrophobic surfaces.

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Characterization of the material-induced elastic–plastic deformations in ultra-precision diamond cutting

Cited by 4 publications

References 44 publications

Numerical simulation of materials-oriented ultra-precision diamond cutting: review and outlook

Numerical simulation of materials-oriented ultra-precision diamond cutting: review and outlook

A theoretical and experimental investigation into surface generation in ultra-precision diamond milling

Advancement of Analytical Model for Hydrophobic Rectangular Pillared Array on Al-Surface and Its Experimental Validation

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