Finite element simulation and experimental investigation of crystallographic orientation-dependent residual stress in diamond cutting of polycrystalline aluminum

Abstract

The residual stress of crystalline materials induced by deformation at grain level strongly correlates with crystal orientation. In the present work, the dependence of residual stress on crystallographic orientation in diamond cutting of polycrystalline aluminum is investigated by crystal plasticity finite element modeling and simulations. Furthermore, corresponding ultra-precision diamond cutting experiments, which have the same parameter setup with the finite element model, are also carried out. The crystallographic orientations of the specimens are depicted by electron back-scattered diffraction characterization, and the surface residual stress is measured by X-ray diffraction. Both experiment and finite element simulation results demonstrate the anisotropic characteristics of the residual stress within machined polycrystalline aluminum, which exhibits the significant correlation with crystallographic orientation. Furthermore, finite element simulations of bi-crystal cutting are also performed, which indicate that the grain boundary also has a strong influence on the generation of residual stress.

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

“…Recently, CPFE model based on the user subroutine (UMAT or VUMAT) has been employed to elucidate the anisotropic cutting mechanisms of polycrystalline copper in diamond cutting [71,72]. As shown in figures 3(b) and (c), the machining surface quality, chip profile and cutting force exhibit significant anisotropic characteristics due to the occurrence of GB migration and anisotropic dislocation activities [22].…”

Development of a flexible high-friction pressure sensor with structural colors for soft gripper fingers

“…During pulling, a normal force of 3.924 N was applied to the polymer. The sample was pulled through 8 mm at 1 mm s 21 . Measurements were terminated 5 s after the specimen began to move, and the maximum static friction force was then calculated (Figure 10(a)).…”

“…three-dimensional trapezoidal structures), and processing precision is low. Ultra-precision machining affords high-level geometric accuracy, 20,21 and it is possible to fabricate three-dimensional trapezoidal shapes using appropriate tools. To fabricate a flexible sensor, the pattern was first created on an aluminum plate and then transferred to a polymer.…”