Crystal anisotropy-dependent shear angle variation in orthogonal cutting of single crystalline copper

Wang, Zhanfeng; Zhang, Junjie; Xu, Zongwei; Zhang, Jianguo; Li, Guo; Zhang, Haijun; Li, Zengqiang; Hassan, Hamad ul; Hartmaier, Alexander; Yan, Yongda; Sun, Tao

doi:10.1016/j.precisioneng.2020.01.006

Cited by 43 publications

(16 citation statements)

References 33 publications

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“…However, the groove morphology and removal state can only be detected after processing and the material removal process could not be dynamically understood. Recently, Zhang et al used linear cutting tools directly connected in SEM to see the chip formation process in material cutting, while this method is complicated and SEM should be modified [ 76 ]. Thus, this method is difficult to be generalized.…”

Section: Analysis Of Simulation Resultsmentioning

confidence: 99%

Molecular Dynamics Study on Tip-Based Nanomachining: A Review

et al. 2020

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Tip-based nanomachining (TBN) approaches has proven to be a powerful and feasible technique for fabrication of microstructures. The molecular dynamics (MD) simulation has been widely applied in TBN approach to explore the mechanism which could not be fully revealed by experiments. This paper reviews the recent scientific progress in MD simulation of TBN approach. The establishing methods of the simulation model for various materials are first presented. Then, the analysis of the machining mechanism for TBN approach is discussed, including cutting force analysis, the analysis of material removal, and the defects analysis in subsurface. Finally, current shortcomings and future prospects of the TBN method in MD simulations are given. It is hopeful that this review can provide certain reference for the follow-up research.

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Section: Analysis Of Simulation Resultsmentioning

confidence: 99%

Molecular Dynamics Study on Tip-Based Nanomachining: A Review

et al. 2020

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“…Especially in micro/nano-cutting, the impact of crystal anisotropy on shear angle cannot be neglected, because the tool-workpiece normally interacts within a single crystal. Wang et al [28] demonstrated that the activated dislocation slip system in the primary deformation zone depends on the relative angle between the cutting direction and the crystal orientation. Thus, to address the crystal anisotropy, a modified shear angle equation is proposed in this study by incorporating Taylor factor (𝑀), which is normally used as an approximate measure of the relative direction of dislocation sliding activities to the crystal orientation, into Lee's shear angle equation as…”

Section: Calculation Of Flow Stress By Hybrid Slip-line Modelmentioning

confidence: 99%

Analytical modelling of cutting forces in ultra-precision fly grooving considering effects of trans-scale chip thickness variation and material microstructure

Sun

et al. 2021

Int J Adv Manuf Technol

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Although ultra-precision fly grooving (UPFG) is widely applied to fabricate micro-structured surfaces, few studies have focused on the cutting force model of UPFG. The unique kinematics of UPFG leads to the trans-scale variation of undeformed chip thickness from nanoscale to microscale, in which case the influence of material microstructure and size effect is prominent. This study proposes an analytical cutting force model for UPFG with full consideration of the kinematics, chip formation mechanism, material microstructure, material elastic recovery, size effect and tool geometry. Specifically, by correlating micro-forming theory to crystal plastic theory, a hybrid slip-line model (HSLM) is developed to determine the flow stress in primary deformation zone, which can quantify the influence of size effect and microstructure, such as grain size, grain boundary, dislocation density and crystal anisotropy, on flow stress. Then, the normal cutting force and frictional cutting force are estimated by analyzing the stress distribution and frictional states at tool-chip interface. The rubbing force induced by material elastic recovery is determined based on indentation theory. Finally, the models are experimentally validated by fly cutting of polycrystalline copper with different machining parameters, and it is also demonstrated that the proposed HSLM can capture the periodic transformation of cutting mechanism in UPFG from ploughing (compressive stress) to shearing (tensile stress) with tool rotation.

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“…More recently, Wang et al presents CPFE modeling and simulations of orthogonal diamond cutting of polycrystalline copper and corresponding experimental validation, in which the crystallographic orientations of individual grains between simulations and experiments are the same with electron backscatter diffraction (EBSD) characterization and corresponding Euler angles mapping [22,28]. They also demonstrated a strong dependence of shearing deformation of single crystalline copper under orthogonal cutting on crystal anisotropy by CPFE simulations and experimental validation [31]. To facilitate the fundamental understanding of the material anisotropy influence on cutting processes of crystalline materials, further theoretical and experimental work is greatly needed.…”

Section: Introductionmentioning

confidence: 99%

Anisotropy-Related Machining Characteristics in Ultra-Precision Diamond Cutting of Crystalline Copper

Wang

Zhang

et al. 2020

Nanomanuf Metrol

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Deformation behavior at grain levels greatly affects the machining characteristics of crystalline materials. In the present work, we investigate the influence of material anisotropy on ultra-precision diamond cutting of single crystalline and polycrystalline copper by experiments and crystal plasticity finite element simulations. Specifically, diamond turning and in situ SEM orthogonal cutting experiments are carried out to provide direct experimental evidence of the material anisotropy-dependent cutting results in terms of machined surface morphology and chip profile. Corresponding numerical simulations with the analysis of built stress further validate experimental results and reveal the mechanisms governing the material anisotropy influence. The above findings provide insight into the fabrication of ultra-smooth surfaces of polycrystalline metals by ultraprecision diamond turning.

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Crystal anisotropy-dependent shear angle variation in orthogonal cutting of single crystalline copper

Cited by 43 publications

References 33 publications

Molecular Dynamics Study on Tip-Based Nanomachining: A Review

Molecular Dynamics Study on Tip-Based Nanomachining: A Review

Analytical modelling of cutting forces in ultra-precision fly grooving considering effects of trans-scale chip thickness variation and material microstructure

Anisotropy-Related Machining Characteristics in Ultra-Precision Diamond Cutting of Crystalline Copper

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